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REVISION O 1 2 3 4 5
DATE March 96
ORIG.BY S Jack
APP.BY
SIGNATURE

Contract:

Client's Name:

Project Title:

Project Location:

Document Category: CLASS

Note

This standard is intended to be used as the starting point for the development a job specific PIS
specification.

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CONTENTS

SECTION SUBJECT

1 INTRODUCTION ..................................................................................3

2 APPLICABLE CODES, STANDARDS AND DRAWINGS ..................................3

3 SCOPE OF WORK ................................................................................4

4 DESIGN PHILOSOPHY ...........................................................................5

5 SOFTWARE BYPASS MANAGEMENT SYSTEM (SBMS) ...............................7

6 DETAILED DESIGN ...............................................................................8

7 I/O SIGNAL DETAILS .......................................................................... 12

8 ON-LINE TESTING FACILITIES .............................................................. 13

9 EVENT RECORDING ........................................................................... 14

10 SYSTEM VALIDATION ........................................................................ 15

11 FACILITIES TO BE PROVIDED AT CONTACTORS OFFICES......................... 16

12 SYSTEM MODIFICATION PROCEDURE................................................... 16

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1 INTRODUCTION

1.1 General

This specification is for the technical requirements of the Protective Instrument System(s)
(PIS).

The Protective Instrument Systems are required to permit a co-ordinated startup and
shutdown of a process and prevent unsafe operation of the process either due to a fault or
incorrect action of the separately installed Distributed Control System (DCS) or any other
control systems.

Terms from IEC 1508 (DRAFT, 1995) are given in bold.

Italized sections are for Foster Wheeler internal use only.

1.2 IEC 1508

This specification is the E/E/PES Safety Requirements Specification in IEC 1508 terms.

2 APPLICABLE CODES, STANDARDS AND DRAWINGS

2.1 Codes & Directives

IEE Guidelines for the documentation of software in industrial computer systems.

Programmable systems only.

European Union EMC directive 89/336/EWG.

EN 50081-2 Generic emission standard; Part 2: Industrial Environment

EN 50082-2 Generic immunity standard; Part 2: Industrial Environment

IEC 1508, Draft, 1995 Functional safety: safety-related systems

IEC 1000-4 Part 1 General Introduction

Part 2 Electrostatic Discharge Requirements
Part 3 Immunity to Radiated Electromagnetic Field
Part 4 Immunity Against Fast Transients/Burst
Part 5 Surge Immunity Requirements
Part 6 Immunity to Conductive Radio Frequency Disturbances

2.2 Client Standards

As applicable.

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2.3 Project Standards

1600A General Notes for Instrumentation

If 1600A is not available for a particular project, 1900A may be

suitable.

97A1 Preparation of Material for Shipment

Only a very limited part of 97A1 is likely to be applicable, if this is so, it may
be worth considering embedding the relevant paragraphs in this specification
rather than calling it up.

61A1 Inspection and Testing of Electronic Control Systems

2.4 Drawings

Earthing Philosophy Drawing

3 SCOPE OF WORK

3.1 General

The PIS=s as defined in this specification shall be independent free standing systems and will
be installed an instrument equipment room.

The PIS supplier’s scope is to include the cabinets containing the PIS modules, cord sets
(proprietary or Elco) and termination boards to be installed in the buyers marshalling
cabinets. These termination boards will be free issued to the buyers marshalling cabinet
supplier.

In the case of systems where the technology does not employ distinct termination boards,
terminals shall be provided in the system cabinets for the termination of the purchasers
multicore cables.

This scope shall include, but not be limited to:-

3.1.1 The design, manufacture, supply, assembly and testing of protective system logic
components, control panels/cabinets, panel front controls and indicators, internal power
supplies and distribution, terminations, labels and any other associated hardware necessary
to form the complete systems described in this specification.

3.1.2 This paragraph is only applicable to programmable system.

The supply of all system software packages, programming devices for on- and off-line
configuration, software instruction and reference manuals, and application programming
required to configure the protective system functions described in this specification.

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3.1.3 Interfacing with the buyer, as necessary, to ensure successful integration of field devices,
alarm systems and power supplies.

3.1.4 Developing a detailed Functional Specification for the system.

3.1.5 Furnishing documentation, spare parts and training as required by this specification.

3.1.6 Complying with the requirements of IEC 1508 for the Realisation Phase and providing input
as required to allow the purchaser to complete other activities in the IEC 1508 lifecycle.

3.2 System Segregation

As required.

In general, the sub-systems for particular items of equipment shall be segregated such that
a fault or maintenance activity in one sub-system will not affect any other sub-systems.

4 DESIGN PHILOSOPHY

4.1 General

All aspects of PIS design will be reviewed by the buyer.

The PIS=s will interface with a DCS. This interface will be used to transmit alarm/status
information from the PIS to the DCS.

Depending on the chosen technology, this link will be either hardwired or a serial data link.

Unless otherwise stated for particular subsystems, it may be assumed that all inputs and
outputs are Afail-safe@, i.e. all field sensor inputs and outputs under normal operating
conditions are energized or logic A1" and will open/de-energize to trip. Transmitters will fail
to the trip condition.

4.2 Acceptable Technology

The following systems are acceptable :-

Delete/add as applicable for a particular project.

4.2.1 Programmable : dual channel fail safe or triple modular redundant.

4.2.2 Solid State Logic: fail safe.

4.2.3 Relay Logic: simple simplex systems only.

Unless otherwise stated for particular systems, PIS=s shall be certified either:-

Class 5 or better to DIN VDE 0116

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Safety Integrity Level 3 to IEC 1508

4.3 System Availability

Mean Time to Spurious Trip (MTTFspurious) shall be greater than 10 years. See IEC 1508
parts 2 and 6.

Supplier shall supply system availability data based on both MIL-HDBK-217 analysis and
historical data for comparable systems. In qualitative terms, the overall system availability is
required to be Ahigh@.

Particular clients may have requirements for system availability analysis.

4.4 Redundancy Requirements

Unless otherwise stated for a particular subsystem, there will be no redundancy of field
inputs and outputs.

Within the PIS at least two self checking channels are required for all trip initiating inputs
and trip devices.

All single point failures within the PIS shall cause an alarm and shall not cause the system to
trip. Subsequent failures shall also be alarmed, but may cause trips.

4.5 Input/Output Data

The buyer will design the logic system using the Honeywell FSCad package. The supplier
shall review these logics, the FSCad files will be made available to the supplier.

The buyer will provide a database (in DBASE IV A.dbf@ format produced by FSCad) that will
list all inputs and outputs to the PIS=s.

If the suppliers system has an equivalent, user friendly, programming/development system,

the supplier may propose this as an alternative to FSCad.

4.6 Chassis Layout

Supplier to propose a suitable layout.

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4.7 I/O Modules

HOLD until the system has been selected.

The range of available modules shall include the following :-

24 V DC Digital Input (for trip inputs)

24 V DC Digital Output, powered with line monitoring capability (for trip outputs)
24 V DC Digital Output, volt free contact (for annunciator and control system repeats)

0-20 mA (or 0-5 V DC) Analog Input

4-20 mA Analog Output

Thermocouple Input, isolated

4.8 Signal Termination

Field wiring will be terminated in the buyers marshalling cabinets. The signals will then be
wired onto termination panels which will be free issued from the PIS supplier to the
marshalling cabinet vendor. Elco type or proprietary FTA cables will be used to connect
these termination panels to the PIS logic cabinets.

If the suppliers system does not have a termination board system for connecting inputs and
outputs, the supplier shall propose an alternative arrangement.

4.9 Serial Communications Links

This section is basically only applicable to programmable systems, parts may be applicable
for non-programmable systems with a data collection PLC etc.

4.9.1 Two MODBUS protocol RS-232 links running at least 9600 baud configured as a redundant
pair are required per system to provide a link to a DCS.

4.9.2 A multidrop MODBUS protocol RS-485 link between is required between all PIS=s and the
Software Bypass Management System (see below).

4.9.3 An RS-422 serial link to a programming station is required per system.

4.9.4 An RS-422 serial link to a sequence of events recorder is required per system.

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5 SOFTWARE BYPASS MANAGEMENT SYSTEM (SBMS)

Programmable systems only.

5.1 General

The SBMS shall consist of a PC linked to all the PIS=s via an RS-485 multi-drop serial link.
This PC shall run an In Touch application which will display process schematics showing
active/inactive trip bypasses.

The supplier is free to offer an alternative system which uses the DCS as the operator
interface (with a suitable system for access control) for the SBMS.

5.2 Requirements

A software bypass is required on every trip initiating input and trip output with the
exception of manual Emergency Shutdown switches and flame scanners. The bypass will be
set/cleared from the SBMS PC. The operation of a bypass will be repeated to the DCS.

The bypass will only inhibit the trip, any alarms associated with a bypassed input will
remain operational. See the section titled ON-LINE TESTING for further information.

6 DETAILED DESIGN

6.1 Area Classification

No field signals will require conditioning by the PIS=s in order to meet any field hazardous
area requirements. Barriers for intrinsically safe field circuits will be located elsewhere.

The PIS=s will be mounted in Asafe@ areas.

6.2 Resets

All sub-systems will require manual resetting once tripped.

6.3 Cabinets

The cabinets shall be strong enough to support all equipment located within them.

The cabinets shall be 800 mm x 800 mm x 2000 mm with a 100 mm plinth.

The cabinets shall be grey externally, white internally and shall have black plinths.

The maximum number of cabinets that may be shipped as a continuous suite is 3.

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The cabinets shall have front and back access doors, the doors shall have a three point lock
mechanism. The doors to all the PIS cabinets shall use the same key, this shall not be the
cabinet vendors Adefault@ key.

Cable entry to the cabinets shall be through the bottom.

Mechanically assisted forced air ventilation shall not be required to maintain the correct
operation of the protective system.

Cabinet layout and power distribution shall include a 25 % allowance for future equipment
to be installed.

A door mounted document pocket shall be provided.

The cabinets shall have removable lifting eyes.

6.4 Environmental Protection

The supplier shall advise the buyer of the allowable environmental limits for the room(s) in
which the PIS equipment is to be installed.

6.5 Electromagnetic Interference

The PIS=s will comply will all applicable European Community EMC directives and shall carry
a CE mark.

Testing shall include the following test to IEC 1000-4.

Part Test Severity

2 Electrostatic Discharge Requirements 4

3 Immunity to Radiated Electromagnetic Field 3

4 Immunity Against Fast Transients/Burst 3

5 Surge Immunity Requirements 4

6 Immunity to Conductive Radio Frequency 2

Disturbances

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6.6 Power Supplies

The buyer will supply each PIS with three 110 V AC feeds. Two of the feed will supply the
PIS, the PIS=s shall be capable of operating with the loss of either of these feeds. The third
supply will power the two utility sockets.

Note that the utility supply may be at a different voltage to the main power feeds.

An isolator shall be provided to terminate each incoming supply. The terminals for the
incoming power cable shall be capable of accepting cable sizes 2.5 to 16 mm2. All
distribution circuits and subcircuits shall be properly fused and isolated. The PIS supplier
shall provide a fuse discrimination schedule for each PIS.

Each signal providing power from the PIS shall be fused in the buyers marshalling cabinets.
Such fuses may be assumed to be 50 mA for transmitters, switches etc and 500 mA for
solenoid valves. The supplier shall advise if this arrangement causes any conflicts with the
PIS=s internal fusing or if such fusing is necessary.

Each PIS shall have redundant power supplies for 24 V DC for field equipment.

Some clients may require some/all of the digital I/O to operate from a higher voltage, e.g.
48 V DC.

Power supplies shall have the 0 V line connected to the Master Reference Ground.

6.7 Earthing

Earthing shall be in accordance with the Earthing Philosophy Drawing.

Each cabinet shall be fitted with two earth bars. On shall be insulated from the cabinet and
provide the Master Reference Ground (MRG), the second shall be bonded to the cabinet
metalwork and shall provide the Safety Ground (SG).

Each bar shall be provided with two clamps suitable for 35 mm2 cables. All sections of
cabinet metalwork shall be bonded together using cable with a minimum cross sectional area
of 6 mm2.

All MRG wiring shall be green sheathed, all SG wiring shall be sheathed yellow/green.

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6.8 Wiring

Cables carrying different power levels shall be segregated.

The screens of any cables that do not originate in a marshalling cabinet shall be connected
to the MRG bar. Cables from marshalling cabinets will have their screens connected to MRG
in the marshalling cabinets, the screens of such cables shall not be connected to ground in
the PIS=s.

All wiring shall be identified using sleeve type markers at both ends. The cable identification
scheme shall be submitted to the buyer for approval. In general, the marker at one end of a
wire shall identify the terminals to which the other end is connected.

All wiring shall be run in PVC trunking complete with lid. The PIS supplier shall ensure that
the trunking is of adequate size to cater for cabling to be run into the cabinets on site.

All stranded wires shall have bootlace type crimp on lugs.

Any wires passing through holes in cabinets shall be fully protected using grommets or
bushes.

Terminals shall be Klippon W series or equivalent. All terminals shall be labeled.

Wires shall be as follows:-

110 V AC 3 core, PVC insulated, PVC sheathed to BS 6500 (2.5 mm2).

2 core as above (1 mm2).

24 V DC / 50 V DC Tri Rated to BS 6231 type CK.

Wire colours shall be:-

220 V AC Overall black sheath with standard brown, blue and

green/yellow conductors OR red, black and green/yellow.

48 V DC Red

24 V DC (digital) Yellow

24 V DC (analogue) Orange

MRG Green

Safety Ground Green/Yellow

Temporary links Purple

Intrinsically Safe Light Blue (if required)

The above is primarily applicable to a relay or solid state logic cabinet, parts of it (e.g. the
wire colours) may be of limited applicability to a semi-standard system cabinet.

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6.9 Labelling

All cabinets shall be clearly labelled at the front and back. The label shall have white lettering
on a red background, lettering to be 10 mm high.

<cabinet reference>

PROTECTIVE INSTRUMENT SYSTEM

<service>

Other labels shall be black lettering on a white background except for warning which shall
be white on red. In general text shall be 5 mm high. Labels are required for :-

Isolators
Power supplies
Switches
Label shall be secured by either stainless steel screws or a suitable adhesive.

6.10 Software Loading

Programmable systems only.

The systems shall be sized such that no more that 50 % of memory or processing capacity
is used when all the applications programs are being run.

6.11 System Booting

Programmable systems only.

The system shall not require manual intervention in order to boot following a power outage.
System startup shall be fully automatic.

The program shall ensure that all subsystems are tripped during the first scan. The following
subsystems are an exception to this rule:-

HOLD

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6.12 Scan Time

The required minimum scan times are:-

HOLD

6.13 Variable/Signal Tagging

Signals and variable internal to the system will be named in accordance with appendix B.

6.14 Miscellaneous

Any equipment on the front of the cabinets shall be readable and operable by a European of
average height in a standing position.

Any lamps shall have a lamp test facility.

7 I/O SIGNAL DETAILS

7.1 Inputs

Inputs shall be redundant within the PIS cabinets.

All inputs will have a variable delay in the logic to prevent transients causing spurious trips.
These delays may be assumed to be 0.5 seconds in duration unless otherwise stated for a
particular input.

7.1.1 Transmitters

A proportion of the inputs to the PIS=s will be 4-20 mA transmitters. The PIS shall alarm on
detection of a Abad@ process variable (PV) (signal less than 3 mA or greater than 21 mA). In
general (1-out-of-1 trips), a bad PV shall cause a trip.

For voted (2-out-of-3) trip inputs, a deviation alarm shall be generated. This alarm will be
active when a transmitter=s value is more than 10 % from the calculated median value.

7.1.2 Process Switches

In general field contacts will be closed in normal operation and will open to trip. Line fault
monitoring is not required except where specifically requested. The contact circuits will
switch 24 V DC.

7.1.3 Emergency Shutdown Switches

Some clients/applications may not require this Adual path@ manual shutdown.

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Control room and local panel mounted ESD switches will have two sets of contacts wired
back to the PIS. One set will be a normal 24 V DC contact input, the other shall bypass the
programmable logic and shall interface directly with the trip outputs. The use of relays as
contact multipliers in this Adirect@ trip path is permissible, Pepperl and Fuch relay cards with
Matsushita sealed relays are acceptable for this service.

7.2 Outputs

Powered outputs will be line monitored. Outputs shall, in general, be redundant.

7.2.1 Solenoid Valves

Final trip elements will in general be solenoid valves (8 W power rating may be assumed).

7.2.2 Motor Control Circuits

Motor control circuits will be controlled via the operation of relays in an interface cabinet (by
others). Relays powered from the PIS may be assumed to be 24 V DC, 2.5 W.

7.2.3 Alarm Contacts

Volt free contacts will be used for signals to alarm annunciators. Contact rating to be 1 A at
24 V DC, contacts to be gold plated. These outputs are not required to be redundant.

8 ON-LINE TESTING FACILITIES

This section will be very client specific, the text below assumes a programmable system.

8.1 Philosophy

Protective systems shall be provided with the necessary facilities to allow the Owner to
perform periodic on-line testing of each PIS=s functionality.

These tests shall include all system components from the field sensors through the logic
system to the final field end device with the exception of the ESD switches and, possibly,
any flame detectors.

Test facilities shall be designed to minimise the disruption to process operations and to
minimise the time the protective system is disabled during testing.

The use of a bypass switch shall not prevent the generation of alarms associated with the
component being bypassed, e.g., if a low level trip is bypassed, detection of a low level by
the PIS will still generate an alarm, but the system will not trip.

The use of the bypass facilities shall not prevent shutdown of the equipment by manual
actuation of the ESD switches.

8.2 Hardware Bypass Switches/Lamps

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One key operated hardwired ATest/Bypass Enable@ switch will be provided for each process
unit or major equipment item and will be located on a console in the control room. Only
with this switch in the AEnable@ position shall the bypass/test facilities controlled from the
Software Bypass Management System PC be enabled. Operation of this switch shall
generate an alarm and light a lamp on the control room console.

8.3 Software Bypasses

Each trip initiator shall have it=s own software bypass switch. In the case of voted trip
inputs (e.g. 2 out of 3), only one bypass is required for each set of inputs.

Similarly, each final trip device shall have it=s own software bypass, except for any 2-out-of-
2 trip arrangements where only one bypass is required.

Each software bypass shall have an associated alarm which will signal it=s operation.

If the serial link between the PIS and bypass management system should fail during testing,
the bypasses shall remain active and an alarm shall be inititated.

9 EVENT RECORDING

9.1 Sequence of Events

Each PIS shall be provided with a sequence of event recorder. Resolution shall be to at least
1 second.

In some cases this functionality may be provided by hardwired inputs to the DCS if it has
sequence of event recording capability or by a serial link to the DCS.

9.2 First-Up

Where groups of alarms on a local panel annunciator are to be driven by the a PIS, Afirst-up@
indication will be provided by the local panel annunciator. In certain cases, the first-up logic
will be in the PIS.

Alarm sequence will be client specific.

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9.3 System Events

Each PIS shall generate alarms when it detects faults within itself.

For each subsystem will generate two common alarms in addition to any associated with
particular inputs and outputs -

PIS XXXX HAS TRIPPED

PIS XXXX BYPASSED

10 SYSTEM VALIDATION

10.1 Validation

The supplier shall plan for protective system validation in parallel with the design effort. This
planning shall include the design of safety verification activities which will demonstrate that
the protective system meets both the functional and integrity requirements. Validation shall
be in accordance with IEC 1508.

10.2 Progress Inspection

See standard 61A1.

10.3 Factory Acceptance Test

See standard 61A1.

10.4 Site Acceptance Test

See standard 61A1.

11 FACILITIES TO BE PROVIDED AT CONTACTORS OFFICES

11.1 Simulator

This is only applicable to programmable systems.

The suppliers quote shall include an option price for supplying a PIS simulation system in
the buyers offices for the duration of the project in order to facilitate the logic development
effort.

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12 SYSTEM MODIFICATION PROCEDURE

Following completion of the Functional Specification, an activity which will be carried out by
the supplier with FWEL and owner input, an formal change control procedure will be put in
place.

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Appendix A - Input/Output Summary

An I/O summary table will be inserted here.

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Appendix B - System Internal Tags

Tags/variables internal to the PIS shall be tagged as follows:-

Tagging philosophy details to be inserted here.

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