SPECIFICATION

FACILITY MANAGEMENT CONTROL SYSTEMS

1.

INTRODUCTION

1.1

SEAGATE will be constructing a new harddisk manufacturing facility to be located

at Kawasan Batu Kawan, Pulau Pinang in Malaysia. This facility will be used for
manufacturing of high efficiency harddisk. The facility is divided into two phases

1.2

This document describes the guidelines to be used for the design of SEAGATE FMCS
package. This document shall be used as a FMCS is of proposals for the scope of supply
and installation described in the package.

1.3

This document shall be for SEAGATE FMCS use only and should not be used as reference
or guidelines for other projects without the approval of SEAGATE Project Director and/or
the author.

2.

TERMINOLOGY

2.1

Specific terminology is used to refer to various contractual parties and items.

contract purposes, the following terms and related definitions shall apply.

2.2

Client
FMCS Vendor

3.

CODES AND STANDARDS

3.1

The entire installation shall be completed in accordance with the following regulations:

3.2

For sub-

SEAGATE Malaysia Sdn Bhd

Organisation appointed by SEAGATE to execute the FMCS scope of
work.

International Electro-technical Commission (IEC) Standards.

Ingress Protection Codes EN 60529. for panels and enclosures.
BS 5308 for Instrumentation Cables
BS EN 62305, 4 Parts, 2006 : Code of practice for protection of structures' against
lighting.
BS 7375, 1996 : Code of practice for distribution of electricity on construction and
building sites.
BS 7430,1998: Code of practice for earthing.
BS 7671,2008 : Requirements for electrical installations. lEE wiring regulation.
Sevententh edition.
BS 7909, 1998 : Code of practice for design and installation of temporary distribution
system delivering a.c. electrical supplies for lighting, technical services and other
entertainment purpose.
BS EN 60529, 1992: Specification for degrees of protection provided by enclosures
(lP Code)
Pressure testing shall be carried out in accordance with ASTM B31.3.
Structured Cabling in accordance with EIA/TIA 568-B and IEC 11801.
International Quality Assurance ISO9001.
Environment Management System Standard ISO14001.
Safety Standards UL standards.

Generally recognized Good Engineering Practice shall be adhered to, at all time during the
installation.

SPECIFICATION

FACILITY MANAGEMENT CONTROL SYSTEMS

3.3

Additionally, the FMCS systems must be designed, supplied tested and constructed,
to fully meet the following applicable requirements:

SEAGATE Corporate Standards.

Malaysia Site Contractor Safety Standards.

Malaysia Codes of Practices.

4.

ABBREVIATIONS

4.1

The following abbreviations are used in this document.

IEC International
IEEE
NEC
NEMA
OSHA
PLC
I/O
IP
ISO
TCP/IP
HMI
ACMV
FMCS
CPU

Electro-technical Commission
Institute of Electrical & Electronic Enqlneer.,
National Electric Code
National Electrical Manufacturers Association
Occupational Safety and Health Administration
Programmable Logic Controller
PLC Input Output
Ingress Protection
International Standards Organisation
Transmission Control Protocol I Internet Protocol
Human Machine Interface (generally to PLC system)
Air Conditioning & Mechanical Ventilation
Facilities Management Control System
Central Processing Unit

5.

SCOPE OF WORKS

5.1

The work covered by this Division of the Specifications and the Drawings, consists of
designing, supplying of equipments / materials / services and performing operations to
complete the Facility Management Control Systems (FMCS) work for this Project. The
primary role of the system is to control and monitor the air conditioning & mechanical
ventilation (ACMV) systems and all the utilities systems throughout the facility, route
alarms, display event data, and collect vital information in the secure databases.

5.2

The FMCS project scope includes controlling and/or monitoring all non-production related
parameter requirements for the building environments, energy management, and general
ACMV and utility systems.

5.3

The building environmental control parameter requirements include, but are not limited
to, heating, cooling, humidification, dehumidification, ventilation and pressurization, The
FMCS systems also control and/or monitor utility generation and distribution systems.

SPECIFICATION

5.4

FACILITY MANAGEMENT CONTROL SYSTEMS

The FMCS software shall be of the latest technology currently being used at the plants
globally and shall provide graphical reporting, alarming, trending, SPC, etc. FMCS design
for this new project shall be developed to include the following systems I/O, necessary
application software & graphics:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

Cooling Tower
Chillers package
CHWP / CWP
Air Handling Units (AHU)
Make-up Air Unit (MAU)
Fan Coil Unit (FCU)
DHF
Supply Fans & Exhaust Fans
Sump Pump
Clean Room Environment
Chilled DI
CDA
Vacuum System
Heat Exchanger
Water Tank
DI Plant
11 KV substation
132 KV Primary Substation
415 V Sub station
UPS
Point of Distribution
Other Pump

Note: Network Architecture Drawing shall be referred for more details. The FMCS project
scope is based on the following:
1.

The FMCS Vendor shall be available within two hours at site in case of breakdown
and have local offices in Malaysia.

2.

Manufacturers' standard products will be preferred when specifying,

minimum lead times can be expected for the project.

3.

Standard point counts and configurations for the site modules and support facilities
will be used.

4.

Redundant Ethernet TCP/IP shall be used as backbone

communication.

or

so that

FMCS systems

SPECIFICATION

FACILITY MANAGEMENT CONTROL SYSTEMS

6.

RESPONSIBILITIES

6.1

Consultant shall be responsible for approval of all engineering deliverable from FMCS vendor.

6.2

FMCS vendor shall be fully responsible for following activities:

a.

The entire project detail engineering, procurement and construction (EPC)

b.

Supply of all network hardware, server/client machines & operating System (OS), software
across the project, FMCS software implementation and graphic development as per standard
user requirement

c.

Supply of all field instruments as per scope column in Instrument Index, P&IDs & FMCS IO
list.

d.

Supply of PLC, Remote IO assembled in Control Panels with all necessary hardware,
terminals, din-rails, power supply, fuse terminals, MCB, as per PLC panel, specification,
system hardware, SCADA software, detail design, integration, installation, errection,
conducting FAT & SAT, testing, start-up and training.

e.

In this project, the FMCS Application software and graphics are to be developed and during
FAT the entire FMCS database shall be transferred to the target machines, downloaded in
the server & client machines.

f.

The nominated FMCS System contractor shall be required to demonstrate minimum of 5 Years
recent, past experience in the design, manufacture and commissioning of the system of
comparable IOs size, type and complexity of projects. The contractor shall be required to have
its own in-house capability and personnel to handle the research & development, engineering,
coordination, procurement, fabrication, installation and commissioning for the FMCS System
of the said project. The contractor shall be required to ensure the new FMCS system able to
integrate with others sub system in the proposal, control logic arrangements, database
migration, GUI Graphical Pages, reporting functionality, communication protocol, Early
Warning SMS Notification system and Auto-Email Reporting System without causing any
malfunction and glitch to the overall operation and management.

g.

The FMCS Subcontractor shall comply with the minimum requirements certification such as
CIDB Grade G7 category ME and ISO9001:2000. The Paid up Capital company of System
Subcontractor shall be minimum RM20,000,000.00 (RM 20 million) and above.

SPECIFICATION

FACILITY MANAGEMENT CONTROL SYSTEMS

7.

SYSTEM GENERAL DESCRIPTION

7.1

GENERAL OVERVIEW

7.1.1

Facility Management System (FMCS) using Redundant Programmable Logic Controllers

with Hot Standby CPU (Redundant PLC) preferable international brand Mitsubishi, Allen
Bradley and Siemens, shall be provided on Unit Rate FMCS is for the control and/or
monitoring of the Air Conditioning & Mechanical Ventilation (ACMV) and Utilities system.

7.1.2

System hardware will include all FMCS devices (Redundant PLC / Remote I/O, etc) with
Fail Safe Circuit Concept, control and communication system cables, chassis for CPU & IO
module, fiber optic cables, fiber optic patch panels, internal panel wiring, din-rail mounted
auxiliary relay, server cabinet, engineering workstation, operator workstation, continuous
historian machine, server machine, provision for field instrument cabling, network cabling,
fiber cabling & network connections and other miscellaneous items to provide for a
complete system. All hardware for utility monitoring & control shall be link via ring
type topology, and the network shall be redundant. HVAC & all other remaining system
hardware (package monitoring interface) shall be simplex (Non-redundant).

7.1.3

System software will include the completion of all control sequences, alarm generation, report
generation, automated schedules and other specific functions that will provide a fully
operational system. The FMCS shall use digital processing with analog and digital inputs
and outputs for system control.

7.1.4

In general, the FMCS shall consist of PLC-based remote FMCS panels that shall directly
interface with sensors and controlled devices. All control and monitoring shall be performed
by use of system inputs and outputs coupled with native system software resident in the
field based controller panels. Sensors and controlled devices shall use a combination of both
analog and digital signals.
All the PLC shall have capability to connect HMl locally using laptop (notebook) for trouble
shooting and / or controlling the parameters in case of network I server failure.

7.1.5

7.2

COMMUNICATION

7.2.1

FMCS System architecture is issued along with this document. The numbers of PLC shown
are indicative (representation). FMCS Vendor to submit detailed System Architecture for
Redundant PLC & Remote IO with their proposal incorporating all their system hardware,
software and interface with FMCS network.

7.2.2

The FMCS architecture shall consist of a minimum of one FMCS controller for each piece of
major equipment. FMCS controllers will be dedicated as non-Impact system with no mixing
allowed.

7.2.3

The FMCS controllers shall be installed in secure and electrically unclassified areas, as close
as possible to the controlled devices to minimize the installation cost. The FMCS panels
shall be located on the walls and/or columns of the building or on fabricated floor-mount
stands.
The control panel enclosures shall also contain fiber optic patch panels, the Input / Output
(I/O) modules or remote I/O modules for particular system field instrumentation.

7.2.4

7.2.5

NETWORKS AND INFRASTRUCTURE

All the PLC shall have a communication port available for accessing the programming
software via laptop in case of connectivity loss between Server and PLC or due to server fail.

SPECIFICATION

FACILITY MANAGEMENT CONTROL SYSTEMS

7.2.6

All individual services BMS such as FFU, VAV, RODI, PQMS, CDA, VESDA and others to
High Level Interface back to the main FMCS required to provide a common specify
communication protocol which is Modbus TCP/IP / MelsecNet / ProfiNet via OPC Server.
Please refer to the Overview FMCS System Architecture Drawing.

7.2.7

All individual services BMS such as FFU, AHU, MAU, VAV, RODI, PQMS, CDA, VESDA
and others shall incorporate proven industry grade PLC system with high reliability hardware.

7.3

DATA HISTORIAN

7.3.1

Data Historian Server will be linked to the FMCS network to collect all the FMCS data
points using OPC Client installed in the Historian Server located at the Process Control
Network. (Note: FMCS Server shall have OPC server as default)

7.3.2

Data collection in the plant is in the form of Data Historian. Preferable Data Historian which
is industrial grade with high reliability.

7.3.3

Owner will provide the template for the data historian tag list for configuration purpose in
FMCSs. FMCS vendor shall provide the details as required by the owner.

7.4
7.4.1

HARDWARE SPECIFICATION
SPECIFICATION FOR PROGRAMMABLE CONTROLLER

a.

PRODUCT

b.

All bidders shall recommend compatible industrial type programmable controller as

PLC preferable international branded brand Mitsubishi, Allen Bradley and Siemens.

GENERAL
1.

The controller used must be industrial grade Redundant programmable logic controller
(PLC).

2.

The Redundant PLC must be able to withstand operating ambient temperature of 0 to

55 deg C, and Relative Humidity of 5% to 95% (non-condensing).

3.

The Redundant PLC to be supplied shall comply with IEC 61131-3 Standard on open
programming platform, which includes Function Block Diagram (FBD), Structured
Text (ST), Relay Ladder Logic (RLL), Instruction List (IL) and Sequential Flow Chart
(SFC) programming languages.

4.

The Redundant PLC shall be modular in design with intelligent modules and these
modules communicate with each other over system bus.

5.

All programming of the PLC shall be possible via a portable notebook computer which
shall be supplied as per the particular specification. The notebook computer shall also
provide local manual control facilities as well as the facility to interrogate the controller
for more detailed diagnostics than those previously mentioned.

SPECIFICATION

FACILITY MANAGEMENT CONTROL SYSTEMS

6.

The programming software shall have the capabilities of:

Create and edit the controller program, variables, and documentation of-line
while not connected to the controller.

Edit the controller program on-line while connected to the controller.

Up/download the controller program, variables and documentation while

connected to the controller.

Start and stop the controller.

Monitor the controller I/O and internal variables.

Force digital signals and inject analog output variables.

7.

All Redundant PLCs shall be capable to be programmed using library functional block
programming tools which shall allow the controller software to be re-used when the
controllers are upgraded in future. The user defined function block shall be developed
within the software package without additional add on accessory and modifications of
code in the user define function blocks can be done online without interrupting the
system.

8.

Each and every PLC shall contain the following features, functions and

32 bit central processor

PID control (multiple loops) capability

Program execution watchdog

Minimum of 124ksteps programming capabilities

Built-in real-time clock

Able to support at least 8192 IO including Remote IO

Digital input shall have LED indication of each input status, and capable to have a
response time of 1ms.
Modules with 32points & above should be connected with connectors. This is to allow
faster replacement of modules in case of module failure and reduce human mistakes in
re-wiring.

9.

10.

Digital outputs shall have an LED to indicate the on/off status of each output, and
capable to have a response time of 1ms.
Modules with 32points & above should be connected with connectors. This is to allow
faster replacement of modules in case of module failure and reduce human mistakes in
re-wiring.

11.

Analog input shall accepts various input signal including but not limited to 0-20 mA,
4-20 mA, 0-5 VDC, 1-5 VDC, 0-10 Vdc, etc. and an accuracy of within +- 0.1% at
ambient temperature.
Analog modules should have 16-bit resolution and conversion time of maximum 50ms.

12.

Analog output shall have output signal range should include but not limited to 0-20
mA, 4-20 mA, 0-5 VDC, 1-5 VDC, 0-10 Vdc, etc. and an accuracy of within +- 0.1%
at ambient temperature.
Analog modules should have 16-bit resolution and conversion time of maximum 50ms.

13.

Each Redundant PLC shall contain its operating system in non-volatile memory.

14.

The processor module has an embedded USB connection to the programming terminal
on the front panel. This link must be possible without the need for a special card at the
Personal Computer end.

SPECIFICATION

FACILITY MANAGEMENT CONTROL SYSTEMS

7.4.2

REDUNDANT PLC HARDWARE SPECIFICATION

a.

A redundant system offers improved system reliability, as it consists of two basic systems, each
of which includes the CPU module, power supply module, network module so that even if a
module error occurs in one basic system, the other one continues to operate without any down
time.
1.

Programmable Logic Controllers provided shall be of Hot Standby function for

robustness and fail-safe operation.

2.

It should consist of 2 separate CPUs (Control & Standby), on 2 separate base plates,
with 2 separate power supply units, and 2 separate network modules.

3.

The Control and Standby CPUs should be connected via a tracking cable for
synchronization of data.

4.

Warm Standby System where 2 standalone controllers are used is NOT acceptable.

5.

The PLC program shall be held initially in the random access memory but after
experience of satisfactory operation has been gained, the program shall be transferred
to EEPROM.

6.

The processors have an internal memory so that they can be used without any additional
memory cartridge. However, they have a slot reserved for a removable cartridge so that
the execution memory can be extended without the need for any dismantling.
Parameters and programs must be able to be written into both of control system and
standby system using software. There is no need to identify each system, and there is
no need to download to Control and Standby CPUs separately. This is to prevent
operator writing 2 different programs into 2 CPUs, causing fatal errors and system
down.

7.

8.

Communication between Redundant PLC CPUs and its Remote I/Os should be
provided in Redundant bus or Ring Topology via fiber optic cable with MelsetNet or
Modbus TCP/IP protocol so that any single break in cable will not cause the system to
be down.

9.

Fiber optic should be used so as to eliminate electrical signal noise causing false alarms.

10.

The fiber optic cable should be direct terminated in the network module and not to
another external switch. This is to reduce another possible point of failure.

11.

I/O modules shall be hot swappable to allow a failed module to be replaced with a
replacement module without shutting down the system.

12.

The data communication shall be carried out in cyclic mode, so that even when system
switching occurs, the standby system is able to receive cyclic data from the other station
in order to continue control.

13.

Redundant PLCs shall be provided with diagnostic capabilities to identify failures to

the module/card level. Diagnostic indication shall include but not be limited to
notification of processor failure, input or output module failure, communications
failure, and battery low. These diagnostics shall all be available as digital outputs for
remote indication and (except communications failure) also available on any
communications bus.
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SPECIFICATION

14.

b.

FACILITY MANAGEMENT CONTROL SYSTEMS

In the event of a CPU replacement, after the CPU module is replaced in standby system,
parameters and programs can be copied from the CPU module of control system to the
new CPU module by executing the transfer command from programming software.
This operation should also be capable of being done via special relays and special
registers.
There should not be a need to use the back-up program from CD-Rom or harddisk,
which may not be the latest version.

The Overall FMCS shall have these minimum requirement :

1.

Automatic controls shall be provided for the Air Conditioning & Mechanical
Ventilation (ACMV), utility monitoring and control. The automatic controls shall
perform as a completely integrated Facility Management System (FMCS).

2.

The facilities, ACMV & Utilities shall be monitored and/or controlled by the FMCS.
Distributed processing and control shall be performed by "standalone" FMCS panels
located in close proximity of the controlled equipment.

3.

The physical FMCS system shall include but not be limited to the following:
a.
b.
c.
d.
e.

Local FMCS panels for controlling (Local start/stop with Local Text
Display, set point change control, etc), monitoring and alarming.
Field instrumentation.
Final control devices (e.q. valves, etc.).
All device connection materials (e.g. control wiring, etc. within panel).
All required system & application software
Capable of communicating or interfacing using a variety of open protocols
such as Modbus TCP/IP, CC-Link or MelsecNet.

4.

The FMCS panels shall be PLC - based and shall perform all system requirements
including but not limited to temperature, pressure, humidity, and flow monitoring
and/or control, as required for ACMV system operation. The FMCS panels shall be
capable of standalone operation, in case of a communication failure on the network.
In short, all the PID controls. logic controls shall be implemented only in the
PLC controller and not in HMI.

5.

PLC programming design must base on fail safe circuit concept.

6.

FMCS Set points & other parameters should have the flexibility to change via HMI
with proper security level. ACMV and other FMCS panels should have local
Start/Stop, Acknowledge /Reset Push buttons that for critical operations.

7.

The FMCS shall be expandable to accommodate future growth without requiring a

change to the system's infrastructure or basic architecture, and without decreasing
the performance of the operator workstations,
servers, FMCS panels or
communication networks. Each distributed FMCS panel shall have a minimum of
30% spare space for future Inputs / Outputs (I/O's).

8.

Supervisory control, data acquisition and reporting shall be performed using dedicated
servers as well as Personal Computer (PC) based HMI workstations. Web Access to
the FMCS is possible via dedicated login security. FMCS system will able to send
critical alarm to dedicated personnel via GSM Modem. Bidder shall provide GPS Time
Synchronization to standardize the time for all the FMCS system.

SPECIFICATION

c.

FACILITY MANAGEMENT CONTROL SYSTEMS

9.

Enclosures shall be suitable for the specific location, lockable via a common keyed
core assembly, contain built-in cable management troughs and contain a removable
backboard.

10.

Field instrumentation for the ACMV and utility systems shall be heavy-duty industrial
grade or high-end commercial grade.

11.

30% spare I/O points in each I/O type shall be considered in each PLC system. All
junction boxes, terminal strips, relays, switches, signal cabling shall have 20 %
spares.

12.

All system hardware components, FMCS panels shall be fully protected by use of
an Uninterruptible Power Supply (UPS) system (provided by others at each FMCS
panel). In addition, the FMCS controllers shall have built-in battery backup to protect
resident programming code.

13.

FMCS network riser (cable tray / trunking layout) will be issued along with this
package that will indicate tentative locations for all PLC FMCS panels. FMCS
Vendor to develop it further to size and locate the panels as required meeting the system
requirements, after contract award.

14.

The Non-impact FMCS will be commissioned using Good Engineering and Good
Installation practices.

Design Requirement:
1.

System International (SI) metric units of measurement shall be used throughout the
project with the exception for the pressure unit: bar, mbar.

2.

External power supply (by others) will be 1ph, 240 VAC (10%), 3-wire system,
50Hz (5%), Un-interrupted
Power source for each PLC Panel and HMI
workstations. Redundant feeders shall be provided (by others) for those panels
catering for utility and require redundant mains supply.

3.

240 VAC I 24V DC I 24V AC power requirements for field instruments shall be
derived, fused and distributed from FMCS control panels.

4.

All powered circuits (I/O modules, etc.) and powered output loops (AO/DO) shall
be individually fused externally.

5.

Power distribution wiring shall be sized to maintain voltage drop in acceptable

levels and meet all electrical codes.

6.

All interface signals to/from MCC & Vendor packages shall be provided with
interposing relays (for both DI & DO) at the FMCS panel end.

7.

Electronic instruments shall be selected to be capable of continuous operation in

specified ambient conditions.

8.

All digital inputs, outputs to/from field devices shall be 24V DC.

9.

Electronic analog instrument transmission and control signals shall be 4-20 mA,
24V DC, 2-wire loop powered with ground.

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SPECIFICATION

FACILITY MANAGEMENT CONTROL SYSTEMS

10.

All analog inputs shall have open circuit / short circuit monitoring

11.

All abnormal process conditions (Alarms) and transition conditions shall be clearly
indicated to the operator (via. HMI) to facilitate easy failure recognition.

12.

Where applicable, control panels shall be Rittal or equivalent make complete with
plinths (wherever applicable), lights, proper ventilation (fans), service receptacle,
etc.

13.

In all areas, panel cable entries shall be preferably at the bottom with cable glands
and separate cable compartment. Enclosure shall be rated with IP54 indoor and
IP55 outdoor area.

14.

Panel cable terminals shall be located near the cable entries to prevent cables/wires
running across the cabinet. Terminals shall be Wieland type mounted on a DIN
type rail. They shall be of the SAK 2.5 (minimum) and numbered on both sides.
No more than one wire shall be connected to any side of terminal block.

15.
16.

Panels shall have safety (dirty) earth and instrument (clean) earth systems (bus bars)
as per instrument system Manufacturer recommendation. Instrument earth shall
be isolated and serve control system and signal cable screens.

17.

Cross-sectional area of instrument earth cables shall not be less than requirement as
per calculation. FMCS vendor shall ensure that the cable sizing is done properly based
on the requirements.

18.

Panel material shall be of Mfr. standard (Mild steal) with epoxy powder coat suitable
for service in indoor or outdoor areas per project requirement.

7.5

FRONT END WORKSTATION

7.5.1

Client workstations shall be installed in the below areas for monitoring & controls.

FMCS Control Room

7.6

SOFTWARE

7.6.1

NETWORK SOFTWARE

a.

FMCS software shall have the following characteristics.

1.

The FMCS software shall be user friendly, plain English based programming
language that does not require the operator to use high level programming languages
such as "C", "C++" or Visual Basic. The software is multi-tasking and works within
the Microsoft Windows 7 or later environment. The software is configured for
the FMCS based upon the approved sequence of operations and shall allow the
operator to control, adjust, modify, alarm, schedule, report, chart, archive and
program the controlled devices. Preferred brand for FMCS Software IFIX or
Wonderware latest version.

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FACILITY MANAGEMENT CONTROL SYSTEMS

2.

All PLC source code listings shall be suitably annotated with comments, tag
numbers, address descriptions and symbols, and PLC files logically named, to
facilitate source code review by Buyer. The above mentioned information should
be in English language. Selection of multi language feature should not be allowed.
All forms of codes and documents both in PLC and HMI should be in English. The
code supplied by vendor should not be hidden. There will not be any portion of the
code to be in any other language other than English. Use of language tables or
reference files or similar to that cannot be accepted.

3.

Any value within the system or displayed on the screen shall be updated within 1
seconds or less or whenever the value changes.

4.

The FMCS software shall be capable of future expansion throughout the site . This
expansion shall not require a major upgrade of the FMCS hardware or software.

5.

The FMCS controller software shall have built-in self-diagnostic routines to report
communication, memory and other failures to the operator.

6.

The FMCS software shall allow the administrator and/or Engineer to define,
construct and modify dynamic colour graphical displays. These graphics shall
display real-time system data and provide the operator with a control interface to
the system.

7.

Colour 3D graphical displays shall be provided by the FMCS Vendor to allow the
operators to zoom in from the building's overview plot plan to the building's floor
plan that shows the controlled devices.

7.6.2

SOFTWARE TOOLS

a.

The software tools shall be based on following controls as minimum.

b.

SEAGATE highly prefers that the FMCS vendor to deliver a solution with HMI
SCADA as COMMON PLATFORM that can integrate without any additional hardware
or software using other brands/vendor's
PLC systems within the same system
architecture.

c.

The HMI SCADA software system must be capable of supporting hundreds of different models,
makes, manufacturers, and protocols of programmable and industrial control devices. Support
for the following should be included as a minimum:
1.
Mitsubishi
2.
Modicon
3.
Siemens
4.
Omron
To permit integration of computer numerical controllers (CNCs), the software system should
preferably include a communications driver and alternately support open architecture standards
and application programming interfaces to allow the development of such a driver as required.
As described earlier, the software system should also support use of DDE and OPC servers to
provide device communications.

d.

FMCS Vendor shall list all the Software licenses including the Windows Operating System
(OS) software for Server and Client machines.

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FACILITY MANAGEMENT CONTROL SYSTEMS

e.

FMCS vendor has to provide Operating System software (Windows Platform) for all the
FMCS Server and Client Machines. FMCS vendor shall supply all the software licenses
required for the PLC, HMI's, Data Historian, workstations, Servers and all the licenses
shall be development type includes run time.

f.

FMCS vendor also need to assured that the System Software propose allow user to design the
architecture with Load Balancing within all operating Server, in order to increase the
reliability of the system.

g.

OPC Client and Server Interface

The FMCS SCADA software system must support an OPC DA and Alarm and Events
interface in both client and server modes. In the server mode, OPC aware applications
(clients) should be able to access data managed by the System. The OPC Client
interface should support the use of third party OPC Device Communication Servers.
The OPC Server interface should allow for point information collected and maintained
by the software system to be sent to OPC applications requesting the data.

The OPC client should allow for browsing of available OPC servers and the published
points.

h.

Graphic Design Tools - The FMCS SCADA software shall have a set of graphical screen
development and creation tools that enable the user to create dynamically updating screens
with graphical representation and access to real-time data from the field controllers as well
as the database. Users shall be able to point and click on objects using a mouse to start and
stop equipment, override system settings and view system events. Creation of custom
defined fields by the user shall also be supported. All screens shall provide the ability to
return to the main administrative menu screen.

i.

SPC. Trending and Graphinq Tools - The FMCS SCADA software shall have a set of trending
and graphing tools that enable the user to create dynamically updating trends and graphs of
real-time data points from the field controllers as well as the database. Users shall be able to
log objects and create trends and graphs that track any combination of logged objects. Users
shall be able to export the results of a trend log using an electronic file format.

j.

Report Generation Tools - The FMCS SCADA software shall have a set of report generation
tools that enable the user to create reports using the built-in programming language and other
available graphical tools. Users shall be able to write programming sequences that process
raw or calculated data and provide reports in a variety of formats including graphical screen
displays and text-based electronic outputs. All real-time and historical data shall be exportable
using an industry standard.

k.

Printing and Output Tools - The FMCS SCADA software shall have a set of printing and
output tools that enable the user to generate output from the system in a variety of formats
including on-screen, on-paper, as well as electronically. This functionality shall enable the
users to produce permanent records of any data gathered within the system including the
results of reports and lists. Each screen should also be easily printable with a simple click
from the mouse button.

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l.

Alarm Generation Tools - The FMCS SCADA software shall have the ability to alarm various
conditions throughout the system. The FMCS shall be capable of generating various alarm
levels by comparing the limits or conditional equations configured in the software with the
data polled from the field instrumentation. The software shall be capable of documenting
alarms in text or graphical format, requiring the operator to acknowledge alarms, and
communicating the alarms to workstations or a remote device. Alarms stored can be queried
and data can be easily retrievable and alarm should be retained for the period of minimum
6 month. Time and Date stamp for all active alarm shall be available.

m.

The system shall be capable of detecting alarm conditions based on the states and values of
the various sensed variables. The alarm conditions shall be detected even if the variables
causing alarms are not currently on the display. Alarms can be filtered based upon location,
priority and other user-selectable criteria
When a new alarm is detected, all client machines will immediately see the new alarm. If
the alarm is acknowledged on one machine then all machines will see that it was
acknowledged.

n.

o.

Alarm limits can be entered by the user at configuration time or from the operator's display
during run-time. Alarm limits are expressed in engineering units.
For more details on alarms & message handling, please discuss with SEAGATE.

p.

Security Tools - The FMCS shall have the ability to preset several levels of security access
to the system's capabilities. Access levels shall be flexible to offer users multiple levels of
access to various items or objects throughout the system. The software shall provide an
audit trail that automatically stores information on user access and changes to the system. This
can be stored in the form of a text file and only accessible via administrator. The file would
have alarms, user login, user checks for action includes start/stop etc.

q.

SMS. Paging and/or Email notification: - The FMCS shall be able to send the alert
notifications to the operator(s) using GSM and/or through an intranet or internet connection.

r.

Web Client: - The FMCS shall have a web browser software to enable user to view any live
parameter of FMCS (reports, alarms, trends, flow, temp, level, pressure, etc ..) from any of
the graphics configured in control system.

7.7

FIELD INSTRUMENTATION AND EQUIPMENT

7.7.1

Remote IO hardware shall be capable of accepting 4- to 20-mA analog signals from twowire or four-wire transmitters, Thermocouples (T/C) and Resistance Temperature Detectors
(RTD's). I/O hardware shall capable of accepting 24VDC digital

7.7.2

All I/O signals shall be isolated. FMCS Vendor shall provide any required external signal
isolators. FMCS Vendor shall identify to SEAGATE where these devices and equipment
have been installed.

7.7.3

FMCS Vendor shall install any required dropping resistors.

7.7.4

FMCS vendor shall provide 24~VDC power at the terminal equipment controller locations
for all two-wire type field transmitters, transducers, relay circuits and digital inputs. FMCS
shall handle a minimum loop impedance of 750~ohms.

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7.8

INTERLOCKS

7.8.1

Critical safety interlocks shall be individually hardwired relays and local to each piece of
equipment. Safety interlocks shall be used for duct-mounted smoke detectors, high current
sensors and process variable limits. The FMCS Vendor shall demonstrate the operation of
the safety interlocks and prove that they comply with the intent of the drawings and
specifications. Control interlocks and any miscellaneous sequences shall be tested. All
alarm and shutdown modes shall be tested for proper operation.

7.8.2

Interlocks need to be displayed on HMI.

7.9

CONTROL PHILOSOPHY

7.9.1

The FMCS system for this scope is to control and monitor all instrumentation signal which
physical point indicate in the overview FMCS Architecture.

7.9.2

All this physical point is related as Digital Input (Dry contact), Digital Output, Analogue Input
(4-20mA) & Analogue Output (4-20mA), this signal will be send to the Redundant PLC for
logic or conditional execution or PID process execution.

7.9.3

All individual services BMS such as FFU, VAV, RODI, PQMS, CDA, VESDA and others will
have localised control system with all related information will channel back to the main FMCS
System on High Level Interface via a common specify communication protocol which is
Modbus TCP/IP or MelsecNet via OPC Server.

7.10

OPERATOR INTERFACES

7.10.1 The client workstations will serve as an operator interface to all of the FMCS controlled
equipment throughout this project. Refer FMCS System Architecture for the locations of
all workstations.

8.

SUMMARY OF WORK

8.1

The FMCS Vendor shall provide, under single responsibility, project management design,
engineering, system configuration, FAT, SAT, Commissioning, site trades coordination,
supply of materials, equipments required in the contract to Design, Fabricate, Supply, Test
and Set to Work as a complete Facility Management System (FMCS)

8.2

The work shall include but not necessarily be limited to the following:

8.2.1

Design, Supply, deliver, test, certify, commission, and set to work all hardware, software,
graphics, networks as required and noted in this FMCS Technical Scope of Work document.

8.2.2

FMCS vendor shall design the system with sufficient capacity to accommodate the facility
requirements as defined in this document. In addition, include 30% excess capacity for
I/O, memory and data collection and storage

8.2.3

All Duct mounted FMCS instruments shall be installed by FMCS vendor, whereas the testing
& commissioning shall be in FMCS Vendor scope.

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8.2.4

Provide equipments, materials and services not specifically mentioned or shown which
may be necessary to complete or perfect the work in a substantial manner and in compliance
with requirements stated or reasonably inferred by the Contract Documents.

8.2.5

Supply, deliver, test, certify, commission and set to work all hardware, software, graphics
and third party interface processors as required and as noted, per SEAGATE documentation.
Systems shall comply with the intent on the drawings, schedules, supporting documentation
and all codes governing the design and installation of such systems. Installations shall comply
with Malaysia Standard Code of Practice for Electrical Installations.

8.2.6

Provide appropriate application engineering and detail design to interpret the intent and user
requirements outlined in this document and associated drawings, narrative, and I/O list such
that all necessary Central Processing Unit (CPU), (I/O) modules and software, hardware,
cables, communication links, system and installation documentation shall be provided.

8.2.7

FMCS vendor shall co-ordinate with respective package vendor for interface testing of
Alarms, Data Historian Tags, Reports, etc from each & every package equipment.

8.2.8

Warehouse at site: FMCS vendor shall make his own arrangement to store all FMCS
materials, panels, equipments, tools, calibrators, consumables, cables, erecting materials,
supporting materials, field instruments, documentation, file rack, etc ... at site in his own
custody. FMCS vendor shall be fully responsible for each and every item in his scope of
supply. SEAGATE shall not be held responsible for any damage, loss or any kind of delay in
project schedule of any single item from FMCS scope.

8.2.9

Marshalling panel, server rack, junction boxes, fiber optic cable, cables, etc. to be installed
at site shall be delivered by FMCS vendor at site with proper documentation.

8.2.10 Project execution / organisation chart shall be submitted by FMCS vendor.

8.2.11 FMCS vendor shall submit the complete Instrument & Power cable schedule (with voltage
drop calculation) from their supplied field Instruments to their PLC panel as per location
drawings. Vendor to note that earthing cable & power cable from earth bar / power
distribution board will be designed & supplied by others.
8.2.12 FMCS vendor shall provide complete network cable schedule, fiber optic cable schedule
(FMCS panel to panel), CAT5 or CAT6 cable schedule.
8.2.13 Site Calibrations of the entire field mounted instruments shall be carried out by FMCS
vendor. FMCS Vendor shall submit relevant test certificates & factory calibration certificates
for all the instruments supplied.
8.2.14 The FMCS Vendor shall liaise with the other Sub-Contractor's to ensure that sufficient
control hardware and instrumentation is supplied to satisfy the requirements of the FMCS
specification. The FMCS Vendor shall ensure that all I/O hardware and software installed
shall integrate with instrumentation and devices supplied to provide control and monitoring
in compliance with the specification and manufacturer's requirements or industry best
practices.

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8.2.15 Provide service, calibration and preventative maintenance procedures and system support
manual for all equipment supplied.
8.2.16 Provide instrumentation and field devices, as indicated in the attached FMCS - Instruments
Index, IOs List, FMCS System Architecture and Instrument Schedule.
8.2.17 FMCS systems propose must allow for future expansion. The software development shall use
a class based approach wherever possible. This approach will allow for additional Air Handling
Units. SCADA Graphics, PLC logics etc shall be provided along with the Commissioning
document & as part of Turn over package. All control module documentation and module
testing shall be included in final project documentation so that it may be leveraged in future
modifications and expansion.
8.2.18 All the documents shall be submitted in electronic format with native files, except
for executed tests which are to be scanned PDF files (provided native unexecuted
PDF files are also included). CAD drawings are required to be submitted in the
current version of AutoCAD and also submitted in PDF format (PDF files of scanned
copies are not acceptable). Five copies of each document are required as hard copy.

8.3

DRAWINGS AND SPECIFICATIONS

8.3.1

The Drawings and the Specifications - the Drawings govern the Specifications for quantity
and location; the Specifications govern the Drawings for quality and performance; in the
event of ambiguity in quality or quantity, the greater-quantity . and the better quality shall
govern.

8.3.2

Discrepancies or conflicts which cannot otherwise be resolved shall be resolved in the

following order of priority:
1.
2.
3.

8.3.3

The Contract.
The General Conditions as modified.
Through Request For Information (RFI)

Other Works and miscellaneous items, not specifically mentioned, but reasonably inferred
for complete the installation including accessories, shall be included in the work. It is the
intent of the Drawings that systems be complete and ready for operation.

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FACILITY MANAGEMENT CONTROL SYSTEMS

8.3.4

FMCS vendor shall submit following minimum (but not limited to) documents drawings for
SEAGATE approval.
1.
Organisation Chart
2.
Project Execution Plan
3.
Bill of Material
4.
Document Numbering System for FMCS vendor's deliverables
5.
Document Distribution Matrix
6.
FMCS System Architecture Drawing (Specific to this project)
7.
Interface Management Plan (for Third Party Interfaces)
8.
Interface Specification (for Third Party Interfaces)
9.
Redundant PLC Functional Design Specification
10.
Cabinet Layout Drawings (FMCS Panels, Marshalling Panels, Server Cabinet, etc .)
11.
Material Specification (Datasheet of each & every item or equipment installed under
FMCS control System)
12.
FAT Procedures, Plan & Report
13.
SAT Procedures, Plan & Report
14.
Integration Test (I-FAT) Procedure (for all third party interfaces)
15.
Power Consumption & Heat Dissipation Data
16.
PLC I/O Allocation Details Drawings
17.
Network Interconnection Drawings
18.
Input / Output Termination Dr
19.
Hook-up Drawings
20.
Panel installation Drawings
21.
Logic Program (for record copy only)
22.
System wise graphics

9.

FACTORY ACCEPTANCE

9.1

GENERAL

9.1.1

The FMCS Vendor shall be responsible for the inspection and quality assurance of materials
and equipment and for the standard of the workmanship. A quality dossier shall be submitted
after testing, complete with certificates and test results. Schedule of FAT shall be included in
the FMCS Vendor's proposal.

9.1.2

The FMCS Vendor shall provide all standard and special tools, test and calibration equipment
necessary for FAT, site installation, SAT and commissioning and to generally service and
maintain the System equipment to its maximum reliability.

9.1.3

FMCS Vendor shall allow Engineer / Client's representatives

documentation at any stage of design and assembly.

9.1.4

Client reserves the right to involve and satisfy himself at each and every stage of testing.
They shall be free to request specific tests on equipment considered necessary by them,
although not listed in this specification. The cost of performing all tests shall be borne by the
FMCS Vendor.

9.1.5

FMCS Vendor shall submit testing, commissioning and acceptance procedure for
review/approval. For hardware, the procedure hall include purpose of test, test definition of
input, procedure, results expected and acceptance criteria. For software, it shall include
details of the method, list of tests, sequence of execution, results expected and acceptance
criteria.

TEST (FAT) & SITE ACCEPTANCE

TEST (SAT)

to review the System and

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9.1.6

All formal testing will be conducted in accordance with written test procedures. FMCS Vendor
shall submit the FAT/ SAT procedures for Client Engineer's approval at least six weeks prior
to commencement of testing.

9.1.7

FMCS Vendor shall demonstrate functional integrity of the System hardware and software.
No material or equipment shall be transported until all required tests have been successfully
completed and the material/ equipment have been certified 'Ready for Shipment' by Engineer
/ Client.

9.1.8

FMCS Vendor to note that acceptance of any equipment or the exemption of inspection/
testing shall in no way absolve the FMCS Vendor of the responsibility for delivering the
equipment meeting all the specified requirements.

10.

COMPUTERISED MAINTENANCE MANAGEMENT INFORMATION SYSTEM

10.1

The attached document serves as Seagate CMMIS technical specification for tenderer, this
system specification document by Seagate covers Computerized Maintenance Management
Information System (CMMIS) with Helpdesk Management System.

11.

TRAINING

11.1

The FMCS Vendor shall provide both classroom and field training for owner's operators,
maintenance and Engineering personnel. Operators are expected to be computer literate
and familiar with basic computer commands and standard software operating systems (e.g.
Microsoft Windows 8). The operators shall have training on the general FMCS along with
the specific requirements and applications of this project. Maintenance personnel supporting
the FMCS equipment shall require hands- on, technical training and are also expected to be
computer literate. For Engineering personnel, PLC programming, HMI configuration etc
shall be provided as additional.

11.2

Provide the services of a competent instructor who will instruct designated owner's
personnel in the operation, maintenance, and programming of the FMCS. Orient the
training specifically to the particular system installed for a given project. Instructors
shall be thoroughly familiar with the subject matter they are to teach. Provide a training
manual for each student, which describes in detail the data included in the program. Provide
all equipment and material required for training.

11.3

Training on the functional operation of the Facility Monitoring System shall include:

Operation of the equipment.

Programming.

Diagnostics & Failure recovery procedures.

Report & Alarm formats (where applicable).

Maintenance and calibration.

Trouble-shooting, diagnostics, and repair instructions.

Sessions shall include both classroom and site training.

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