SPECIFICATION

FOR

FOUNDATION Fieldbus (FF) System

BI-3751

MAINTAIN GAS COMPRESSION CAPACITY

ABQAIQ PLANTS

TABLE OF CONTENTS1.0 INTRODUCTION 3

1.1 General 31.2 Scope of Work 31.3 Saudi Aramco Standards and this Specification 31.4 Fisher-Rosemount Instrument Use 31.5 Fieldbus Design Process 3

2.0 DEFINITIONS 43.0 APPLICABLE DOCUMENTS 4

3.1 Saudi Aramco Materials Systems Specifications 43.2 Saudi Aramco Standard Drawings 43.3 Industry Standards 43.4 Company Standards and manuals 4

4.0 SEGMENT DESIGN 54.1 Basic Segment Loading Requirements 54.2 Segment Executions Times 54.3 Requirements for PID Control in the Field Device 64.4 Final Element Configured Fail State 64.5 Risk Area and Segment Segregation 7

5.0 WIRING DESIGN 75.1 Segment Topology 75.2 Distance Constraints 95.3 Spurs 95.4 Cable Types 95.5 Field Junction Boxes 105.6 Wiring Polarity 105.7 Field Wiring Technique 105.8 Fieldbus Power Consumption 115.9 Voltage Drop 115.10 Shielding 125.11 Grounding 12

6.0 FIELDBUS DEVICES 126.1 Fieldbus Device Minimum Requirements 126.2 The Fisher-Rosemount H1 Smart Carrier shall not be used. 12

7.0 NON-DEVICE ELEMENT SECTION 127.1 Foundation Fieldbus Power Supplies (FFPS) 127.2 Terminators 137.3 Bulk Power Supplies (BPS) 137.4 Repeater 13

8.0 CONFIGURATION 138.1 Configuration Guidelines: 138.2 Block Naming 148.3 System Controller and Control Module Naming 14

9 DOCUMENTATION 149.1 Piping & Instrumentation Diagrams (P&ID’s) 149.2 Instrument Segment Diagrams 159.3 Instrument Specification Sheets (ISS) 15

10.0 FACTORY ACCEPTANCE TEST (FAT) 1511.0 SITE ACCEPTANCE TEST (sat) 1612.0 INSTALLATION AND CHECKOUT 1613.0 MAINTENANCE SHOP FIELDBUS SYSTEM & TOOLS 1614.0 FIELDBUS SPARE PARTS & DELTAV REVISION LEVEL UPDATE PROGRAM 1715.0 BENCHMARKING 18

1.0 INTRODUCTION

1.1 General

This engineering specification covers the minimum requirements for the designand installation of an H1 FOUNDATIONTM Fieldbus system based on the 31.25kbits/s physical layer per ISA S50.02.

1.2 Scope of Work

This specification defines the requirement for design, specification, installation,configuration, commissioning and maintenance for a FOUNDATION Fieldbusbased control systems. As such, this specification is for use by both the LSTKcontractor and Control System Vendor. This specification will only discuss thevoltage mode (parallel coupling) medium attachment unit, as defined in ISAS50.02, operating at a signal speed of 31.25 kilobits per second (i.e. H1).

1.3 Saudi Aramco Standards and this Specification

The FOUNDATION Fieldbus system shall adhere to all existing Saudi AramcoEngineering Standards (SAES) and Specifications (SAMSS), except as definedin this document.

The term Saudi Aramco within this document shall be defined as SaudiAramco PMT, Proponent, and Process Control Systems Division (PCSD).

1.4 Fisher-Rosemount Instrument Use

Fisher-Rosemount instruments shall be used for all instruments on this project(measurements and final elements), including non-smart conventional 4-20mA,4-20mA/HART, and Foundation Fieldbus instruments. The Vendor/LSTK shallobtain Saudi Aramco approval for any non-Fisher-Rosemount instrument usedfor this project.

The Fisher-Rosemount H1 Smart Carrier shall not be used.

1.5 Fieldbus Design Process

Commentary: The fieldbus system design process will be somewhat differentthan that for a traditional Distributed Control System (DCS). Tasksassociated with DCS implementation; such as instrument selection,instrument placement, junction box design, etc. are commonlycompleted independently of each other. This is not the case, however,for the design of a fieldbus based system. Since many traditionalcontrol functions can reside in fieldbus instruments, designconsiderations traditionally associated with the DCS must now expandto incorporate field instrumentation.

A typical fieldbus segment consists of the following components, referenceFigure 1:• H1 - Foundation Fieldbus Interface Card

• FFPS - Foundation Fieldbus Power Supply

• BPS - Bulk Power Supply (24 Vdc)

• T - Terminator

• Fieldbus devices, (e.g. transmitters, transducers, etc.)

Figure 1 Fieldbus Segment Components

2.0 DEFINITIONSAll definitions of Fieldbus terms and acronyms used in this document can be found atthe Foundation website www.fieldbus.org.

3.0 APPLICABLE DOCUMENTSSince this document defines requirements for the complete FOUNDATION Fieldbussystem, it includes aspects of control and types of field instrumentation. For this reason,all Saudi Aramco Instrumentation standards and specifications are applicable. TheLSTK/Vendor shall comply with the latest issue of these documents.

3.1 Saudi Aramco Materials Systems Specifications

All All 34-SAMSS Specifications

3.2 Saudi Aramco Standard Drawings

All All SAES-J Standards

3.3 Industry Standards

ISA S50.02 Fieldbus Standard for Use in Industrial Control Systems,Part 2: Physical Layer Specification and ServiceDefinition

FF-816 FOUNDATIONTM Specification 31.25 kbits/s PhysicalLayer Profile

3.4 Company Standards and manuals

Saudi Aramco Drafting Manuals, Volumes I & II

H1 TFFPS

BPS

T

4.0 SEGMENT DESIGN

4.1 Basic Segment Loading Requirements

Commentary: Prior to defining Fieldbus segments, the process control strategyshould be complete, the P&IDs available, and instruments selected withlocations determined.

4.1.1 Redundant H1 Interface cards shall be used for all segments.

4.1.2 Segments shall contain 8 or fewer devices unless approved in writing by theSaudi Aramco representative.

Exception: For segments containing monitor only devices, up to 12 devicesmay be connected to one (1) segment. Monitor only device does notparticipate in any control function.

4.1.3 Segments shall contain no more than 2 final elements (e.g. control valve, MOV,AOV, damper actuators,), unless approved in writing by the Saudi Aramcorepresentative.

Commentary: While the H1 segment might be able to support six or morecontrol loops, other factors, such as number of function blocks, scanrates, risk assessment, etc. present limitations which dictates fewer.

4.1.4 The primary LAS shall reside in the host controller card and the backup LASshall reside in a monitoring only (i.e. not used for control) fieldbus device or adedicated LAS device. Each segment shall have an enabled backup LAS.

4.1.5 Redundant process measurements shall be on separate H1 segments.

4.1.6 Segments shall be designed for 25% spare capacity, i.e. FFPS supply currentand function block capacity. Calculation of 25% spare current capacity shallinclude one spur fault condition of 50mA additional load, reference FieldbusPower Consumption Section.

Commentary: One DeltaV H1 interface card (port 1 and 2) is limited to 64function blocks.

4.2 Segment Executions Times

4.2.1 The number of devices per segment, for the following required execution times,shall be as follows:

• For segments with monitor only measurements, limit segment to 12 devices.

• For loops requiring 1-second execution time, limit segment to 8 devices.

• For loops requiring 0.5-second execution time, limit segment to 4 - 8devices.

• For loops requiring 0.25-second execution time, limit segment to ≤ 3 deviceswith a maximum of one (1) final control element.

Commentary: Function block execution frequencies must be compatible withboth system loading and process control objectives. The executionfrequency of all function blocks contained within a single fieldbussegment is defined by that segment’s macrocycle time. Thismacrocycle time, which can typically range from 250ms to severalseconds (depending on the nature of the device used), is configured for

each fieldbus segment. The order of execution is automaticallydetermined based on the connections between function blocks on thefieldbus segment. If a faster control loop is added to a segmentcontaining slower loops, then the macrocycle times of all devicesresiding on the segment must be adjusted to accommodate it. Somecare should be exercised as the segment can become overloaded.

The number of function blocks residing on a single H1 card's segmentmust be taken into account. Each H1 card has two segments (ports)and the card is limited to a total of 64 function blocks. The limitation inthe number of function blocks per H1 card is based on the number offunction blocks that are actually configured in the devices, not on thenumber of function blocks that are available in the devices.

4.3 Requirements for PID Control in the Field Device

4.3.1 Simple/Single Loop PID Control in the Segment

For simple/single PID control in the field device, all function blocks that make upthat control loop must reside on the same segment. When all function blocks ofa simple/single PID control loop cannot reside on the same segment, the PIDcontrol shall reside in the host system.

When simple/single loop PID control is implemented in the field device, the PIDfunction block shall be located in the final control element.

Commentary: Both the valve and transmitter typically have a PID blockavailable, so locating the PID block in one device over another device isnot a trivial issue. There are a number of reasons that the PID blockmay be located in the valve or in a transmitter. Execution speed,advanced diagnostics, failure mode, and operator access are a few ofthe factors to be considered when locating where the PID block resides.As with conventional control systems, loop, and device failure modesneed to be determined and the proper course of fail action identified foreach control loop.

4.3.2 Cascade Control

The preferred cascade control configuration is to locate all function blocks anddevices on the same segment. For PID control in the field for this case, theprimary PID controller may reside in the primary measurement transmitter andsecondary PID controllers may reside in the secondary final element.

If the primary and secondary loops have devices and function blocks onseparate segments, the primary PID control shall reside in the DCS. In thiscase, the secondary loop PID control may reside in the secondary final element,if all secondary loop function blocks and devices reside on the same segment.

4.4 Final Element Configured Fail State

All final control elements shall have a configured fail-state on loss of segmentcommunication.

Commentary:

The valve has two different fail states depending on failure mode:1) configured fail state 2) mechanical fail-state.

For example, on loss of communication, the valve can be configured to holdlast position. Loss of communication can be caused by:• H1 card failure, if a backup LAS is not used.• Accidental removal of terminator• Loss of input signal to the valve (i.e. AI function block).

The valve will go to its mechanical fail-state position (i.e. spring returnposition) on loss of power. Loss of power can be caused by:• Broken wire• Shorted wire• Failed power conditioner• Loss of DC supply voltage to power conditioner

4.5 Risk Area and I/O Grouping Segregation

4.5.1 The FOUNDATION Fieldbus segment design shall follow the risk area and I/Ogrouping philosophy as defined by this project and by BI-3712 and BI-3731.

4.5.2 Grouping of instrumentation devices and function blocks on the Fieldbussegments shall be such that a failure of one segment shall not affect more thanone I/O group.

4.5.3 Risk Area I/O group assignments and the associated segment loading is subjectto approval by Saudi Aramco.

5.0 WIRING DESIGN

5.1 Segment Topology

The fieldbus installation shall use the tree, spur, or combination topology asshown in Figure 2. Do not use the daisy chain topology.

Commentary:

Components of fieldbus segments can be connected together in variousarchitectures known as topologies. The topology selected is usually drivenby the physical plant location of the devices in order to reduce installationcosts. Hence, plot plans are used in addition to P&ID's and instrumentindexes in the design of a fieldbus segment.

Most often, after the above design considerations are weighed, the followingthree topologies are used: (See Figure 2)• A tree topology is used when several related instruments are physically

located close to each other. A fieldbus junction box is located close tothe instruments with spurs extending from it to each instrument.

• A spur topology is used when several related instruments are located inthe same direction from the host device but not necessarily close toeach other. In this case, a trunk line is extended from the host to the

farthest instrument and spurs are extended from it as it runs past eachinstrument.

• A spur/tree topology is used when some combination of the aboveinstrument locales exists. Note that spurs are permitted to extend onlyfrom trunk lines and not from other spur lines.

The daisy chain topology is not used because devices cannot be added orremoved from a segment during operation without disrupting service toother devices.

Trunk

Spur

To H1Card

Tree Topology

JunctionBox (JB)

To H1Card

Spur Topology

To H1Card

JunctionBox

CombinationTopology

To H1Card

Daisy-ChainTopology

(JB) (JB)(JB)(JB)

(JB)

Do Not Use

Figure 2 - Fieldbus Topologies

5.2 Distance Constraints

The maximum allowed length of a fieldbus segment is 1900 meters (6232 ft.).This total segment length is computed by adding the length of the main trunkline and all the spurs that extend from it. Therefore,

Total Segment Length = Trunk + All Spurs

Commentary: The maximum length given is from the ISA S50.02 Fieldbusstandard. From field experience we have found these lengths to beconservative. As stated in this specification, the length of a segment islimited by voltage drop and signal quality (i.e. attenuation anddistortion). As Saudi Aramco gains field experience these length limitswill be revised to reflect real world experience.

The Saudi Aramco representative must approve, in writing, the use of a differentcable type from the cables specified.

5.3 Spurs

5.3.1 Only one (1) FF device shall be connected to each spur.

5.3.2 A spur is a drop off of the main trunk line. The trunk is considered to be themain cable run and will contain segment terminators at each end. Refer toTable 1 for the maximum spur length based on the total number of devices onthe segment.

Commentary: Since we are using the spurguarded (short circuit protection)Megablock the segment design is limited to one (1) device per spur.

TotalDevices onSegment

1 Device perSpur

1-12 394 ft. (120 m)

13-14 295 ft. (90 m)

15-18 197 ft. (60 m)

Table 1 - Recommended Spur Lengths per ISA S50.02

5.4 Cable Types

5.4.1 Trunk (Homerun) Cabling

Either Type A cable (i.e. Belden 3076F) or Aramcos standard 18 AWG multi-pair, individually shielded cable for analogue signals, per 34-SAMSS-913, shallbe used for all trunk wiring.

Twenty five percent (25%) spare pairs shall be provided for all Fieldbussegment trunk cables, with a minimum of one spare pair. This requirementincludes spares on trunk cable runs between marshalling racks and junctionboxes, and between junction boxes.

Commentary: The decision to use multi-pair or single pair trunk cablingdepends on the number of segments installed in the field junction box.Typically, the trunk cable will be a multi-pair cable if you have more than

one segment in the junction box. Note that under all circumstances,there will be at least 2 Fieldbus trunk pairs run together (one active andone spare minimum).

5.4.2 Spur Cables

Type A cable (#18 AWG), as defined in ISA S50.02, shall be used for all spurcabling.

5.4.3 Color Coding

For all FF cables, spur and trunk, the outer jacket color shall be orange.

For all FF cables, spur and trunk, the conductor color code shall be;(+ signal) ............. black(- signal) .............. whitedrain/shield.......... bare tinned copper conductor

5.5 Field Junction Boxes

All trunk and spur connections in the field junction boxes, including pass throughtrunk pairs without spurs, shall be terminated on Relcom Megablock terminalblocks. All Megablocks shall have the integral short circuit protector for spurconnections, (i.e. SpurGuardTM).

Exception: Inactive spare Fieldbus trunk pairs may be terminated onconventional terminal blocks, per Saudi Aramco standards.

Only one Fieldbus device may be connected to each spur.

Commentary: Megablocks with integral Spurguard short circuit protectors willprevent a fault (short circuit) in the device or spur cable run frombringing the entire FF segment down. On a fault condition, themaximum current delivered to a spur is ~60 mA. Therefore, for worst-case design where a Fieldbus device consumes 10mA quiescentcurrent, and additional 50mA load is added when this spur is short-circuited.

5.6 Wiring Polarity

Wiring polarity shall be maintained throughout the segment design andinstallation.

Commentary: Wiring polarity is critical because some fieldbus devices arepolarity sensitive. Wired with the wrong polarity, a device may short-circuit the segment or simply not operate.

5.7 Field Wiring Technique

The termination at the FF device shall be the same as analogue devices,reference SAES-J-902.

No modular wiring components shall be used (i.e. passive multiport junctions(bricks), molded connector cordsets, plug in junction connectors, etc.).

5.8 Fieldbus Power Consumption

5.8.1 Fieldbus devices may be powered either from the segment (bus) or locallypowered depending on the device design. Bus-powered devices typicallyrequire 10-30 mA of current at between 9 and 32 volts.

5.8.2 The total current draw from devices on the segment must not exceed the ratingof the FFBS Fieldbus power supply. The segment design must take intoaccount:

A) Total device quiescent current draw.

B) One spur short circuit fault (i.e. ~50 mA additional current draw).

C) 25% additional current load above A and B above.

Note: The acronym ‘FFPS’ will be used in lieu of ‘fieldbus power supply’throughout this document to avoid confusion between the bulk powersupply (BPS) and the ‘fieldbus power supply’.

5.8.3 The number of bus powered (two-wire) devices on a segment is limited by thefollowing factors:• Output voltage of the FFPS.• Current consumption of each device.• Location of device on the segment, (i.e. voltage drop).• Location of the FFPS.• Resistance of each section of cable, (i.e. cable type).• Minimum operating voltage of each device.• Additional current consumption due to one spur short circuit fault, ~50 mA.

Commentary: The length of a fieldbus wiring system and the number of deviceson a segment are limited by power distribution, attenuation and signaldistortion. The ISA S50.02 estimates how long a fieldbus cable can beand still have adequate signal quality, (i.e. acceptable attenuation anddistortion). Calculating power distribution for a segment is relativelysimple and can be easily performed.

5.9 Voltage Drop

5.9.1 Circuit analysis shall be carried out for each fieldbus segment to determine theoperating voltage at each device. The calculated voltage at the device shallexceed the devices minimum voltage rating by 4 volts, (e.g. minimum Vdcrequired by device = 9 volts, therefore the calculated minimum voltage seen atthe device shall be 13 Vdc). The calculated voltage at each device shall beshown on the Instrument Segment Diagram (ISD).

Commentary: The additional 4-volts at each device has been specified as aspare power margin for future device additions to the segment.

Per the FOUNDATION fieldbus specification, field devices must sense aDC voltage between 9 and 32 volts for proper operation.

The power used by fieldbus devices varies by device type andmanufacturer. Specific minimum voltage and current requirements arecontained in the product specifications for each device. The voltageand current requirement for each device shall be taken intoconsideration while conducting the circuit analysis of the segment. A

Fieldbus Foundation certified device is required to be capable ofoperating at ≥ 9 Vdc.

5.10 Shielding

Fieldbus cable shield terminations shall be as per conventional Saudi Aramcorequirements.

5.11 Grounding

Field instruments and instrument stands shall be grounded as per conventionalSaudi Aramco requirements.

6.0 FIELDBUS DEVICES

6.1 Fieldbus Device Minimum Requirements

The following shall be the minimum features available in all Fieldbus devices:

• Foundation Fieldbus Certification as having passed the InteroperabilityTest Kit (ITK), revision 4.1.

• The FF Device and all function blocks shall be tested and certified bythe vendor of the control system Host DCS.

• Function blocks shall be downloadable into the devices by the end user.

• Capable of performing continuous diagnostics, including self-testfunctions and be able to give specific diagnostic information at the MMI.

• All Fieldbus instruments shall have automated software wizards toallow easy set-up and calibration from the MMI.

6.2 The Fisher-Rosemount H1 Smart Carrier shall not be used.

7.0 NON-DEVICE ELEMENT SECTION

7.1 Foundation Fieldbus Power Supplies (FFPS)

7.1.1 FFPSs are required for each fieldbus segment.

7.1.2 FFPSs shall be redundant and output current limited.

Commentary: If an ordinary power supply were to be used to power theFieldbus, the power supply would absorb signals on the cable becauseit would try to maintain a constant voltage level. For this reason, anordinary power supply has to be conditioned for fieldbus. This is doneby putting an inductor between the power supply and the fieldbus wiring.The inductor lets the DC power on the wiring but prevents signals fromgoing into the power supply. In practice, a real inductor is not used butan electronic equivalent. The electronic inductor circuit has the addedadvantage of limiting the current provided to the segment if the cable isshorted.

7.1.3 FFPS units may be ganged together with common BPS feeds, and commonalarms, for efficiency. No more than eight (8) FFPS units may be ganged

together. The primary BPS shall feed one end of the ganged FFPSs, and thesecondary BPS shall feed the other end of the gang. All ganged FFPSs shallbe associated with the same risk area.

Commentary: The Relcom redundant power supply (FFPS) can be ordered withpre-made wiring jumpers. These jumpers are used to efficientlydistribute power and to series alarms to multiple (ganged) FFPS units.In this way, a gang of Relcom redundant FFPSs may be fed from a oneprimary and one secondary BPS feed.

7.1.4 FFPSs shall be supplied from redundant feeds from the bulk power supplies(BPS). Each feed from the BPS is to be independently fused.

7.1.5 Failure or faults in any of the redundant FFPS shall be annunciated in the Hostsystem. A common alarm for all FFPSs in a single cabinet may be used.

7.2 Terminators

7.2.1 Each fieldbus segment must have exactly two terminators. The wiring betweenthe two terminators is defined as the trunk.

7.2.2 The field terminator shall be installed in the field Junction Box (JB). Thisterminator shall be installed at the farthest end of the trunk.

Commentary: When a signal travels on a cable and encounters a discontinuity,such as a wire open or short, it produces a reflection. The portion of thesignal that echoes from the discontinuity travels in the oppositedirection. The reflection is a form of noise that distorts the signal. Aterminator is used to prevent a reflection at the ends of a fieldbus cable.A fieldbus terminator consists of a 1µF capacitor in series with a 100 Ωresistor.

Some of the wiring components previously discussed may haveterminators built into them, (e.g. FFPS). These terminators may bepermanently installed, turned on or off using a dipswitch, or placed intouse by a wiring jumper.

7.3 Bulk Power Supplies (BPS)

7.3.1 The bulk power supply feeding the FFPSs shall be from the DCS redundantpower distribution panels specified in BE-391623.

7.3.2 Overcurrent protection shall be provided for each feed supplying power to anindividual or gang of FFPSs.

7.4 Repeater

Repeaters shall not be used.

8.0 CONFIGURATION

8.1 Configuration Guidelines:

8.1.1 The LSTK/Control System Vendor shall create a guideline control philosophy forthe DeltaV control system. The guideline shall define all typical controlmodules, complete with configured function blocks and all parameters defined.This guideline shall set function block and control module philosophy for this

and future projects using the DeltaV and Fieldbus control system. Theconfiguration guideline shall be reviewed and approved by Saudi Aramco.

8.1.2 As part of the guideline, a narrative shall be provided for each typical functionblock and control module, to describe in detail the setting of parameter and thesubsequent blocks/module operation. Included shall be narrative discussion onparameter configuration and operation for signal status, bad valuedetermination, failure mode switching, Initialization feature, anti-reset windupfeature, etc.

8.2 Block Naming

8.2.1 Each function block shall use the standard DeltaV naming convention, which isthe field device tag name for its main descriptive name and a 'suffix' defining thefunction or block type for which it is defined, (e.g. FT5010_AI, FT5010_AO,etc.).

8.2.2 In the event a device has more than one identical function block, they shall beuniquely identified with a sequential numeral, e.g. FT5010_AI_1 , FT5010_AI_2,etc.

8.3 System Controller and Control Module Naming

8.3.1 Each DeltaV controller and control module will be named based on areasonable and consistent format developed by the LSTK/Vendor. The namingconvention shall be applicable to this and all future projects. Saudi Aramcoshall approve the naming convention.

9 DOCUMENTATIONFoundation Fieldbus system design requires the same documentation asconventional control system designs. The documentation requirements shall beper the DCS specification (BE-391623). However, some documents must bealtered for Foundation Fieldbus architecture. Documentation alterations,additions, and deletions required for FF use are defined below.

9.1 Piping & Instrumentation Diagrams (P&IDs)

9.1.1 The fieldbus instrumentation shall be shown on the P&ID per Saudi Aramcostandards with the following exceptions:

• Fieldbus instrument balloons shall be conventional, with the addition ofa Foundation Fieldbus indication on the top right side of the instrumentbubble, shown as: FF

• The line symbology for FF signal wiring shall be shown as a doubledash with an open bubble - - o - - o - - o - -

• The control or logic function balloons shall be shown independent of thehardware in which it is contained.

9.1.2 All functions within the same field device shall be tagged with the same number,with individual function lettering appropriate for the application.

Commentary: For example using a multi-variable Coriolis meter, the instrumenttagging would be FT-1010, DT-1010, and TT-1010 for flow, density andtemperature, respectively.

9.1.3 Multivariable Fieldbus transmitters (e.g. multiple process measurements fromthe same transmitter) shall be represented with connected instrument balloons.

9.2 Instrument Segment Diagrams

The Instrument Loop Diagram (ILD) shall be replaced with an InstrumentSegment Diagram (ISD). The ISD is a hardware-wiring diagram intended toshow the physical connections and layout of the segment. Soft data includingdisplay, function block, and configuration data shall not be shown. In addition tostandard loop drawing information, ISDs shall include the following FF systemdetails:• The title block shall contain the segment name. The segment name shall

consist of the Controller Name, Card Number and Port Number. Forexample if the Controller name is 01, card number is 08 and we are usingPort 1, the segment name will be ISD-010801.

• All segment connections inclusive of the H1 interface card, BPS, FFPS,through the field devices, terminations, junction boxes, and terminators.

• All segment and field device tagging.• All spur cables shall be labelled with the instrument tag number.• All cable distances with voltage drop calculation results.• Risk area and I/O grouping.• The Backup LAS device shall be identified.• Terminator locations shall be clearly identified.• Refer to Appendix A for the required segment-drawing format.

9.3 Instrument Specification Sheets (ISS)

For FOUNDATION Fieldbus instrumentation the standard Saudi Aramco ISSsshall be used with the following line item additions:• LAS capable (yes/no)• Minimum Operating Voltage (Vdc)• Quiescent Current Draw (mA)• Polarity Sensitive Termination (yes/no)• DD revision level• Channel number and Description, (e.g. Channel 1 - Sensor 1,

Channel 2 - Body Temperature, Channel 3 - Sensor 2, etc.).• Function Blocks Available, (e.g. AI_1, AI_2, PID_1, etc.)

10.0 FACTORY ACCEPTANCE TEST (FAT)10.1 Vendor shall develop a separate written test plan and test procedure for the

FOUNDATION Fieldbus FAT.

10.2 Factory acceptance test shall be per the DCS specification (BE-391623) withthe following additions for FOUNDATION Fieldbus:

10.2.1 A complete functional test shall be conducted for one of each FF device used onthis project (i.e. third-party and F-R products). This test will include, but is notlimited to, plug-and-play interconnectivity to Host system; verify access to alldevice function blocks, and actual device operation, (e.g. stroke valves/MOVs,simulate process inputs for transmitters, etc.).

10.2.2 The test shall include a calibration and setup for each type of FF device.Examples are changing RTD sensor types, calibrating transmitter span, zeroingP & DP transmitters, zeroing elevation on DP level transmitters, setup &calibration of new positioner on a control valve, MOV setup, AOV setup, etc.The intent of this requirement is to verify the ease of access to calibrationwizards and setup procedures via the Host system.

10.2.3 All calibration and setup procedures, for each device, shall be documented indetail by the Vendor and approved by Saudi Aramco.

10.2.4 Vendor shall develop a redundancy fail-over test procedure for the H1 interfacecards and Fieldbus power supplies. The test shall verify that automatic fail overshall not cause an upset, (i.e. I/O signal bumps, loss of operator view, modechanges, etc.). All H1 interface cards and FFPS shall be tested. Saudi Aramcoshall approve the test procedures.

10.2.5 Each segment (port), including spares, shall be operationally tested by liveconnection of at least one Fieldbus device. The Fieldbus device shall beconnected to the terminal block designated for the field wiring or system cable.

11.0 SITE ACCEPTANCE TEST (SAT)11.1 The SAT test shall contain the same scope as covered in the FAT.

12.0 INSTALLATION AND CHECKOUT 12.1 The LSTK/Vendor shall develop a separate installation and checkout procedure

for the field FF system. This procedure shall be approved in writing by SaudiAramco.

13.0 MAINTENANCE SHOP FIELDBUS SYSTEM & TOOLS 13.1 The LSTK/Vendor shall supply and install a complete DeltaV Fieldbus

maintenance system in the Abqaiq Plants maintenance shop(s) specified. Theintent of this system is to allow Fieldbus instrument troubleshooting, calibration,and setup in the Instrument Maintenance shops.

13.2 The Maintenance DeltaV Fieldbus system will include all system hardware,software, and auxiliary equipment required to connect and maintain Fieldbusdevices in the shop. Equipment shall include but not be limited to a DeltaVcontrol system with dual Operator/Engineering workstations will completesoftware, control network with appropriate switches, DeltaV chassis withcontroller & power supply, redundant H1 cards, Bulk and FOUNDATIONFieldbus power supply (FFPS), and Relcom 8 spur Megablocks withSpurguards. The Megablocks shall be externally mounted and easily accessibleto maintenance technicians. All workstations will be mounted in appropriate

shop-proof furniture. The DeltaV chassis, power supplies, wiring and terminalblocks will be pre-wired and installed in an easy to access, caster mountedcabinet.

13.3 Vendor shall supply, as required, all standard and special tools, test software,and test and calibration equipment required for the DeltaV Fieldbus system.Vendor shall provide a list of the above tools, test and calibration equipment toSaudi Aramco and LSTK Contractor for review and approval.

13.4 Standard equipment includes items available from standard catalogs. The list ofthe standard tools and testing and calibration equipment required shall state thefollowing:

• Description of its service or simulation application

• Manufacturer and Catalog No

• Quantity recommended.

13.5 Vendor shall provide design and performance specifications for all special tools,test software, and test and calibration equipment.

13.6 The Fieldbus tools provided shall include, but not be limited to, three Fluke 123industrial scope meters, and three each Relcom FBT3, FBT4, and FBT5Fieldbus testers.

14.0 FIELDBUS SPARE PARTS & DELTAV REVISIONLEVEL UPDATE PROGRAM

14.1 The LSTK/Vendor shall develop a Fieldbus device spare parts managementprogram for Saudi Aramco. This program shall provide management of:

• Stocking a sufficient quantity of Fieldbus spare instruments and associatedsoftware.

• Management, tracking, and update of Fieldbus spare instruments revisionlevels.

• Stocking a sufficient number of Fieldbus non-device element hardware.

14.2 The LSTK/Vendor shall develop and put in place an update program thatassures the DeltaV system revision level stays current.

Commentary: The DeltaV must be kept current to assure it will work with new Fieldbusinstrument revisions. A current revision level DeltaV is also backwardscompatible with older Fieldbus instrument revisions.

While they look exactly the same, Fieldbus instruments are completely differentfrom, and not replaceable by, conventional instruments. Thus, spare Fieldbusand conventional instruments must be kept segregated and identified differently.In addition, Fieldbus instruments may have associated software that must bestored with it.

For these reasons, a complete Fieldbus instrument spare parts managementprogram must be developed.

15.0 BENCHMARKING15.1 The LSTK/Control System Vendor shall Benchmark the project cost

implementation differences between PROVOX, DeltaV Classic, and DeltaVFOUNDATION Fieldbus control systems used on this project. The Benchmarkwill be used to define actual savings attributable to the use of DeltaV Classicover PROVOX, and separately, DeltaV Fieldbus over DeltaV Classic.

15.2 The Benchmarking data provided by the LSTK/Control System Vendor shallquantify the total project costs expended, and where applicable, man-hoursexpended. In addition, the different technology affects on project schedule shallbe recorded.

15.3 Costs shall be averaged on a per point basis, separated by AI, AO, DI, DO, PIDLoop, etc. point types. To obtain representative average costs, all point typesfor a particular technology (PROVOX, DeltaV Classic, DeltaV Fieldbus) shall beaveraged to obtain the per point cost.

15.4 All data shall be in spreadsheet and graphic format. The data will be providedwith a complete descriptive report describing the data and its significance.

15.5 To provide resolution in where cost differences occur, the benchmarking shallshow cost and manpower data in the follow project activities:

Design:

• Segment diagram versus loop drawing generation.

• Control configuration man-hours and costs

• Total documentation man-hours and costs.

• Total design schedule.

• Marshalling and DCS footprint.

Hardware Costs:

• Field Instrument only cost.

• Complete control system minus field instrument- cost.

• Complete control system costs.

Installation Costs:

• Shop Instrument calibration check and positioner setup.

• Wiring + termination manpower costs and schedule.

• Homerun only costs.

• OPC to auxiliary system versus conventional Modbus.

Checkout & Commissioning

• Loop check.

• Device configuration download.

• Instrument example problems & resolution.

• Manpower and Cost savings in F-R versus 3rd Partycheckout/commissioning.

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