PEL-TP-00-INS-SP-002 - Rev 0

JASA KONSULTASI
PERENCANAAN PEKERJAAN
INSTRUMENTASI TANKI STORAGE
CPO DI PERAK
PROCESS CONTROL SYSTEM SPECIFICATION
Contract No : HK.0502/296.1/P.III- Page 1 of 40

Doc. No : PEL-TP-00-INS-SP-002
2016
EMPLOYER : PT. PELABUHAN INDONESIA III (PERSERO)
JASA KONSULTASI PERENCANAAN PEKERJAAN

PROJECT TITLE :
INSTRUMENTASI TANKI STORAGE CPO DI PERAK
CONTRACT NO. : HK.0502/296.1/P.III-2016
0 08/08/2016 Issued For Bid ND DW BA
REV PRP'D CHK'D APV'D

DATE DESCRIPTION PELINDO III
. OSTRADA INDONESIA
JASA KONSULTASI
CPO DI PERAK

2016
REVISION HISTORICAL SHEET
Rev. Date Page Description
0 08/08/2016 All New doc

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TABLE OF CONTENT
TABLE OF CONTENT............................................................................................................. 3
1. INTRODUCTION.................................................................................................................. 5
1.1 Project Overview..................................................................................................................5
1.2 Scope................................................................................................................................... 5
2. DEFINITION......................................................................................................................... 5
3. CODE, STANDARD & REFERENCE...................................................................................6
4. PROCESS CONTROL AND SAFETY SYSTEM GENERAL DESIGN..................................7
3.1 System Recovery................................................................................................................. 8
3.2 Maintainability....................................................................................................................... 8
3.3 Modularity and Standardization..............................................................................................8
3.4 Electrical Transients, Electro Magnetical Interferece, and Radio Frequency Interference
9
3.5 System Control Panel........................................................................................................... 9
4. PROCESS CONTROL SYSTEM........................................................................................10
4.1 PCS Functional Requirement.............................................................................................10
4.2 PCS Hardware Requirement..............................................................................................11
4.2.1 Power Supply Module.......................................................................................................11
4.2.2 PCS Controller Unit........................................................................................................... 11
4.2.3 I/O Modules....................................................................................................................... 12
4.3 PCS Software Requirement.................................................................................................13
5. SAFETY SYSTEM.............................................................................................................. 14
5.1 Functional Requirement.....................................................................................................15
5.2 Safety System Hardware Requirement................................................................................17
5.2.1 Power Supply Modules.....................................................................................................18
5.2.2 Processor Modules........................................................................................................... 18
5.2.3 I/O Modules....................................................................................................................... 19
6. SYSTEM INTEGRATION...................................................................................................20
6.1 Communication System......................................................................................................20
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6.1.1. Communication Network Interface................................................................................21

6.2. System Diagnostics............................................................................................................ 22
6.3 Packaged Control System..................................................................................................23
7. OPERATOR INTERFACE REQUIREMENTS.....................................................................23
7.1 ENGINEERING WORKSTATION.......................................................................................25
7.2 Operator Work Station (OWS)............................................................................................27
7.3 Server................................................................................................................................. 29
8. ALARM MANAGEMENT....................................................................................................30
9. INSPECTION AND TESTING.............................................................................................31
10. DOCUMENTATION............................................................................................................ 34
11. TRAINING.......................................................................................................................... 36
11.1 Scope................................................................................................................................ 36
11.2 OperatorTraining................................................................................................................ 36
11.3 Instrument Technician Training..........................................................................................36
11.4 Engineer and Supervisor Training......................................................................................37
12. PREPARATION FOR SHIPMENT......................................................................................37
13. QUALITY ASSURANCE SYSTEM.....................................................................................39
13.1 General.............................................................................................................................. 39
13.2 Quality Audits..................................................................................................................... 39
14. WARRANTY/GUARANTEE................................................................................................40
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1. INTRODUCTION
1.1 Project Overview
Currently PT. Pelindo III (Persero) is managing development of CPO Storage Tank in
Nilam Tengah Terminal at Tanjung Perak Port, Surabaya.
This project is expected to fulfill goals and objectives, which is to serve CPO supply.
The CPO come from Floating Storage or tanker at Tanjung Perak Port which will be
streamed through CPO pipeline transmission to fulfill the need of Crude Palm Oil at
Nilam Tengah Terminal.
This development of Storage Tank will be equipped with Integrated Monitoring

System for CPO management which utilize Terminal Automation System (TAS).The
TA act as controller according to its operation and safety philosophy.
1.2 Scope
This specification defines the Process Control System Specification to be used for
“Jasa Konsultasi Perencanaan Pekerjaan Instrumentasi Tanki Storage CPO di
Perak”.
2. DEFINITION
PROJECT  Jasa Konsultasi Perencanaan Pekerjaan Instrumentasi
Tanki Storage CPO di Perak.
COMPANY  PT Pelindo III (Persero) as an owner of the PROJECT
CONSULTANT  PT Ostrada Indonesia appointed by COMPANY as their
Engineering Consultant.
CONTRACTOR  PT Weltes Energi Nusantara
VENDOR/SUPPLIER  A company providing specific materials or services
required for the construction of the Facility
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3. CODE, STANDARD & REFERENCE

This specification document based to the last edition code and standard as shown
below:
 API RP 551 : Process Measurement Instrumentation

 API RP 554 : Process Instrumentation and Control
 BS 6121 : Cable Glands
 BS 6755 : Test of Valves
 IEC 60228 : Conductors of Insulated Cables
 IEC 61000-4 : Electromagnetic Compatibility - Testing & Measurement
 IEC 60348 : Safety Requirements for Electronic Measuring
Apparatus
 IEC 60529 : Classification of Degree of Protection Provided by
Enclosures – Ingress Protection (IP) Code
 IEC 60584 : Thermocouple
 IEC 60654-1 : Industrial Process Measurement and Control
Equipment - Operating Conditions - Part 1: Climatic
conditions
 IEC 60751 : Industrial Platinum Resistance Thermometer Sensors-
RTD
 IEC 60770 : Transmitters for use in industrial-process control system
 IEC 61331 : Fire Resistant Cable Test
 IEEE-802.3 : Local Area Network.
 IEEESTD.830 : Guide to Software Requirement Specifications.
 IEEESTD.1012 : Standard for Software Verification and Validation Plans.
 IEEESTD.1016 : Recommended Practice for Software Design Descriptions
 IEEE472-74 : Guide for Surge With stand Capacity (SWC) Test.
 ISA5.1 : Instrumentation Symbols and Identification
 ISA S 5.2 : Binary logic diagram for process operations
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 ISA 5.3 : Graphic Symbols for Distributed Controls
4. PROCESS CONTROL AND SAFETY SYSTEM GENERAL DESIGN

PCS shall be provided in the new Control Room with all monitoring and control
requirements for the plants and the operator interface via monitors, operator
keyboards and printers. From a PCS workstation, an operator shall be able to control
and monitor process parameters / variables as indicated on the P&IDs or applicable
drawings.
VENDOR shall provide a complete system and guarantee that, once installed, it shall
be able to perform all functions as described in the specification.
The system shall be provided with all necessary associated modular devices
(processor modules, power supply units, termination modules, cards, terminals,
cabinet wiring, maintenance diagnostic equipment, etc) installed in cabinets and
completely wired, and ready to connect incoming cables.
The hardware, software and auxiliary components of the control systems provided by
VENDOR shall be suitable for industrial environmental use.
Compatibility of software and hardware releases for all equipment shall be ensured
by VENDOR.
Software shall be from the latest release. The effect of failures shall be minimized as
much as possible by using redundancy and "fail safe" design. The process control
and safety system shall allow for on-line expansion without interruption and/or
interference to current plant operation.
Time shall be synchronized throughout the Control Systems including the Safety
Shutdown System.
3.1 System Recovery
The proposed equipments, including the operator station shall restart automatically
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after a power supply restoration without the assistance of highly qualified system
maintenance technician.
3.2 Maintainability
System design shall incorporate a comprehensive set of diagnostic features including

history logging, alarming and reporting facilities.
System fault diagnostics shall have the capability to identify faults of individual
modules.
No spurious plant or process equipment shutdowns shall be initiated during any

correctly performed maintenance on the Process Control System.
Failure and subsequent replacement of any module shall not affect the working of
other components or cause a system failure. System modules shall be provided with
LED'S for normal and fault indication.
3.3 Modularity and Standardization
The process control and safety system shall be designed and standardized to
minimize the amount of spare parts and the operators and maintenance technicians
training requirements for operator and maintenance personnel.
The hardware, software, and auxiliary components of the process control and safety
system proposed by VENDOR shall be "standard type" from the selected
manufacturer and shall be available as "off the shelf' standard product.
VENDOR shall detail all software used for the system. Special software, if required,
shall be highlighted.
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3.4 Electrical Transients, Electro Magnetical Interferece, and Radio Frequency

Interference
The process control and safety system shall be supplied with provisions for
protection against system errors and hardware damage resulting from electrical
transients on power or signal wiring. These transients include those generated by
switching large electrical loads, by power line faults, and due to lightning strikes and
lightning induced surged on power or signal cables. The system shall also exhibit a
high degree of immunity to RFI.
3.5 System Control Panel
Complete system and marshalling cabinet shall be supplied for Process Control and
Safety System. The cabinet typically standard size of 800mm(W) x 800mm(D) x
2100mm(H), with 4 mm thickness, including 100 mm plinth, with front and rear
access. The cabinet shall meet the standard of IP 21, and equipped with ventilation,
fan, and lighting. Lifting eyes shall be provided on the top of the cabinets.
Field side and system side termination and cross wiring between the field side and
system side terminals shall be provided. All equipments, terminals, MCBs, cables,
and wires shall be clearly tagged for ease of identification and maintenance. Cables
and wires shall be routed within cable wire ducts with sufficient spare space within
the ducts for future modification. Grounding bars shall be provided.
The powered terminal for input and powered output loops shall be of the fused type
and the return terminal shall be of the disconnect/knife type, volt free contact outputs
shall have disconnect type terminal,
All cabinets supplied by VENDOR shall be fully equipped, wired and ready to be
installed on site. VENDOR shall take into account the spare capacity/expandability.
Spare terminal shall be provided 20 percent of spare I/O.

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4. PROCESS CONTROL SYSTEM
4.1 PCS Functional Requirement
The Process Control system shall perform all process control functions indicated on
the applicable project P&ID's and related process control narrative documents. The
process control system shall be designed and manufactured to perform the main
following process operation tasks :
a. Controlling MOV
b. Pumps control Monitoring
c. and control of product flow
d. Monitoring and control of product transaction and transfer
e. Tank Management System
f. Alerting system
g. Data acquisition storage and file management
h. Data trend and historic storage display and reporting
i. Alarm, event, change log and status display and reporting
j. Communication with other systems
k. Automatic diagnostic
The Process Control System (PCS) shall be configured with redundant, parallel
processors. Design of system must be such to maximize reliability of PCS. Failure of
oneprocessor shall result in take-over of the control by the other processor without
processupset or loss of control / data archiving functions.
The process control system shall be able to implement PID control, ratio control, and
cascade control.
Controller shall be also capable to provide auxiliary function like multiplication,

division, square root, addition, subtraction, lead/lag, override, selection, HH/H/L/LL
alarms (for input and output signals and calculated values), dead time, calculation on
PV, output characterization, totalization.
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During operation, change over from auto to manual output mode or change over from
local to remote set point shall be bump less.
The process control system shall be able to handle a digital inputs and outputs to
operate valves and pumps. This will require the use of pre-configured digital "blocks"
including several inputs and several outputs to implement :
a. Auto/manual processing
b. On/off control, discrepancy alarming
c. Interlocking
d. Duty/stand-by selection and change over
4.2 PCS Hardware Requirement

4.2.1 Power Supply Module
The PCS shall operate with redundant power supply. Each power supply shall be
individually capable of supporting the full power load of all modules. The power
supply modules shall be fitted with status and diagnostic LED'S (as a minimum,
module status, and fault). The power supply module shall be replaceable without
affecting the working of any other modules in the PCS. Power supply modules shall
receive 230 V AC, 50 Hz, from UPS.
4.2.2 PCS Controller Unit
Controllers units shall be based on latest version of microprocessors capable of

receiving and transmitting data and performing control and/or sequence functions.
Microprocessors shall have non-volatile memory and be able to perform their control
functions without access to the operator interface or communication network.
Operator interface or network failure shall not disturb the process.
Loss of the active CPU shall cause system outputs to freeze at their last position or
to go to predefined fail safe conditions.
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The PCS shall be provided with individual battery back-up to maintain the integrity of
the memory for six (6) months in case of a power failure. Battery low voltage
detection shall be included as part of the diagnostic alarm.
4.2.3 I/O Modules
Input/output modules shall be replaceable without removing the signal wiring

between the module and the termination module and without using special tool.
VENDOR shall provide the complete reference and data-sheet of proposed I/O
modules.
The supplied I/O modules shall include 20% installed spares of each type of I/Os for
future modification provision.
a. Analog Input
Analogue input module can use either active or passive circuit. Analogue input
circuit shall be powered by 24 VDC from the PCS through galvanic isolator.
Circuit type for field inputs shall be 4-20 mA DC 2 wires.
Analogue input modules shall have transmitter out-of-range fault detection, as

well as open and short circuit, and earth faults detection.
b. Analogue Output
The Analogue output shall be 4-20 mA DC 2 wires. The field converters shall be
powered with 24 VDC directly from the PCS through galvanic isolator.
c. Digital input
All input shall be powered by system 24 VDC and shall have optical isolation.
Normal status of digital inputs shall be either normally open or close. Digital
input modules shall be configurable and shall include facilities to ensure that any
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"chatter" or "bounce" occurring during contact closure does not initiate spurious
alarm.
d. Digital Output
Different types of digital outputs shall be required to enable control to actuating

devices. The following type of outputs are foreseen :
 24 V DC powered outputs
 Volt free output rated 2A @ 24 VDC powered by other system.
The contact outputs shall be configurable to allow for :
 maintained, latching, pulse contact

 Normally open/normally closed outputs. Fail-safe configurable position for
each channel is required
 Pulsed outputs. The pulse duration shall be individually adjustable.
4.3 PCS Software Requirement
All the software and hardware engineering tools necessary to build and maintain the
configuration of operator control stations, PCS controller units, and computer
interfaces shall be provided by VENDOR. VENDOR shall clearly identify and
describe these tools, at bid stage and provide them in sufficient quantity for normal
operation. These engineering tools shall be available in an Engineering Workstation
installed in control room.
Standard operating system software, with full documentation, shall be provided by

VENDOR. VENDOR shall provide configuration software to meet COMPANY'S
specific requirements.
The following control and calculation algorithms shall be provided, as a minimum:

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 Ladder Logic,
 Timer Functions,
 Arithmetic Functions,
 Counter Functions,
 Logic Instructions,
 Comparison Instructions,
 PID Instructions,
 Computing Instructions,
 Functional Block,
 Block Transfer Instructions,
 Sequencer Instructions,
 Diagnostic Instructions,
 File Management, and
 File Arithmetic and Logic
Vendor of DCS or PLC and ESD shall provide the flow chart for every step in the
whole system will be executed by controller, supervision, and data acquisition from
start system until shutdown system in according with their system
5. SAFETY SYSTEM
Process control system shall be integrated with Safety Instrumented System (SIS) to
measure risk and prevent accident due to fault system on process condition.
Safety Integrity Level is a way to indicate the tolerable failure rate of a particular
safety function (Based on IEC 61508). Standards require the assignment of atarget
SIL for any new or retrofitted SIF within the SIS. The assignment of the target SIL is
adecision requiring the extension of the Hazards Analysis. The SIL assignment is
based on the amount of risk reduction that is necessary to maintain the risk at
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anacceptable level. All of the SIS design,operationand maintenance choices must

then beverified against the target SIL.This ensures that the SIS can mitigate the
assigned process risk.
Vendor shall be provides architecture of SIS that certified withsafety level SIL 3. The
Vendor shall state any restrictions and/or exceptions to meeting this integrity level.
Software for applicatitionpropose with VTA / vendor to advice.
Fire & Gas System includes :
 Fire-area control philosophy.

 Automatic control and interlocking control.
5.1 Functional Requirement
The principal aims and objectives of the safety system are:
 Protection of personnel
 Protection of environment
 Protection of plant and equipment
The logic shall act as in accordance with the Cause and Effect matrix to:
 Detect any abnormal operational or equipment condition

 React to this condition automatically by shutting down and/or isolating sections
of the plant, or the entire plant
 Required sections of the plant
 Shutdown of plant utilities
 Isolate the electrical supplies,
The ESD, PSD, and F&G system shall be combined into one common safety system
with segregation on 110 modules level.
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The Safety System shall be designed on a fail safe basis so that its failure shall place
the plant process in safe shutdown conditions. However, some circuits shall be
energized to trip such as extinguishing system or deluge valve opening command.
Such circuits shall be line monitored by the system.
Shutdown Initiation
Shutdown shall be initiated either automatically or manually.
a. Automatic initiation
Shutdowns shall be designed to operate automatically when the process is

outside normal operating limits and when a dangerous situation is likely to
occur before an operator could intervene.
b. Manual initiation
Shutdown may be initiated manually either locally at the equipment or

remotely from the Control Room ESD push-button.
Shutdown command shall be latched and manually reset before start-up.

Some shutdown might be automatically reset when required by process.
Inhibit Function
Inhibit function shall be provided when necessary.
In order to be able to start-up equipment or sections of process, it shall be necessary

to inhibit some inputs to the safety system as sensor signal may be in abnormal state
prior to start-up and could cause a shutdown. Such inhibits are designated as "start-
up inhibits".
Activation of start-up inhibits shall be carried out manually by operator via operator
control station display during a start-up sequence. It will only inhibit the shutdown
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action; input status monitoring will remain operable. Each start- up inhibit function
shall be reset automatically either by the sensor signal returning to the normal or
healthy state, after a dedicated step of the equipment start-up sequence or after a
predetermined time delay.
Inhibits which have to be made in order to be able to safely perform maintenance

work on sensors during process operation, are designated as "maintenance inhibits".
This inhibit facility shall be provided for each Safety System input (ESD and F&G)
and ESD pushbuttons.
Individual inhibit status indication shall also be provided with alarm at the operator
control station so that inhibited function can not be left engaged.
All inhibit functions shall be protected by password to prevent the unauthorized use
of these facilities.
Fire Detection System
Flame detectors and related action devices shall be directly controlled and monitored
by the Fire Detection System (FDS), which is integrated within the Safety system.
Refer to Datasheet for Flame detectors for detail of the FDS sensors.
5.2 Safety System Hardware Requirement
The safety system shall be implemented using a redundant controllers PLC

architecture.
System components shall be rack-mounted, modular design, plug-in type. Modules

shall be replaceable without the need for special tools.
All modules shall be replaceable on line without causing further system damage. Re-
initialization of replacement module shall be automatic.
Identification and location of faults and status shall be automatic, by means of

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indicators (LED) located on each module with displays of faults on maintenance /

inhibit local console and with common fault alarm and status displayed on operator
control station.
5.2.1 Power Supply Modules

The safety system PLC shall operate with redundant power supply. Each power
supply shall be individually capable of supporting the full power load of all modules.
The power supply modules shall be fitted with status and diagnostic LED'S (as a
minimum, module status, and fault). The power supply module shall be replaceable
without affecting the working of any other modules in the PLC. Power supply
modules shall receive 230 V AC, 50 Hz from UPS. Processor Modules
5.2.2 Processor Modules

Redundancy shall be provided on controller unit level to ensure control integrity for all
control loops and their availability. In the event of hardware failure, the back up
controllers shall automatically take over all card functions and control strategies of
primary controller in less than one second, in case of malfunction of the later thus
achieving continued automatic control without process disturbance or control upset
(no change over in manual when in automatic mode).
Primary to back up controller change over shall be fully transparent to the operator
and to the plant operations. Fail-over of any controller unit shall cause an alarm to be
generated on the operator control stations and logged. Loss of both the active and
redundant CPU shall cause system outputs to freeze at their last position or to go to
predefined fail safe conditions. Scan time of the Safety Shutdown System shall not
exceed 250 msec.
5.2.3 I/O Modules

Input/output modules shall be replaceable without removing the signal wiring
between the module and the termination module and without using special tool.
VENDOR shall provide the complete reference and data-sheet of proposed I10
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modules. The supplied I/O modules shall include 20% installed spares of each type
of 110s for future modification provision.
a. Analog Input
Analogue input module can use either active or passive circuit. Analogue input
circuit shall be powered by 24 VDC supply from the SIS through galvanic
isolator. Circuit type for field inputs shall support 4-20 mA DC 2 wires for
transmitters, 0-20mA DC three (3) wires for F&G detectors, and active/four
wires 4-20 mAdevices, such as open path gas detectors (if applicable).
Analogue input modules shall have transmitter out-of-range fault detection, as

well as open and short circuit, and earth faults detection.
b. Digital Input
Digital input modules shall be configurable and shall include facilities to ensure
that any "chatter" or "bounce" occurring during contact closure does not initiate
spurious alarm. Normal status of digital inputs shall be either normally open or
close. All input shall be powered by system 24 VDC, and shall have optical
isolation. Line monitored digital input shall be provided for non fail safe signals.
c. Analog Output
The Analogue output shall be 4-20 mA DC 2 wires. The field converters shall
be powered with 24 VDC directly from the SCS through galvanic isolator.
d. Digital Output
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Different types of digital outputs shall be required to enable control to actuating

devices. The following type of outputs are foreseen :
 24 V DC powered outputs
 24 VDC Line Monitored outputs
 Volt free output rated 2A@24 VDC powered by other system.
The contact outputs shall be configurable to allow for:
 Maintained, latching, pulse contact

 Normally open/normally closed outputs. Fail-safe configurable position for
each channel is required
 Pulsed outputs. The pulse duration shall be individually adjustable.
Line monitored digital output shall be provided for non failsafe signals.
6. SYSTEM INTEGRATION
The PCS VENDOR shall be responsible for integration of the Terminal Automation
System (TAS). The PCS VENDOR together with CONTRACTOR and respective
subsystem Vendor shall make sure the compatibility of the subsystem with the PCS.
Preliminary communication test might be conducted when necessary.
6.1 Communication System
The communication system shall provide high speed, reliable, secure and error-free
communications between all devices resident on the network.
VENDOR shall provide the calculated load on the data communication network,
which shall be less than 65 %, including load generated by devices of future network
expansion.
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The main communication network shall consist of redundant Ethernet network. The
redundant Ethernet network shall connect the process control system and safety
system to the operator control stations and servers. This redundant network
capability shall be a standard feature of the control systems.
Servers and Operator stations connected to the network shall be utilized with dual
NIC. Redundant network switches shall also be supplied.
Communication to higher level of monitoring and control shall be through firewall.
6.1.1. Communication Network Interface

Data communications network interface devices shall be available with the capability
of interfacing various devices with the Data Communications Networks. Process
related and control functions shall utilize Control Net network communications or
equal. HMI operator workstations shall utilize Ethernet. Examples of such interfaces
are:
 fibre optic communication,

 Communication with other PLCs, Modbus, or Ethernet, or Serial.
 Data communications via Ethernet network to HMI operator workstations
 Engineering workstation computer for programming or maintenance on serial link
or Network / Ethernet network interfaces,
 Ethernet extended to communication network.
The automation system communication shall be on the high-speed local area

network (LAN) confirming to IEEE 802.3 standards and utilize industry standard
protocols with minimum 100 Mbps / 1 Gbps bandwidth and shall be OPC (OLE for
Process Control) compliant or standard server.
* OLE (Object Linking and Embedding)
6.2. System Diagnostics

The offered systems shall be capable of providing continuous full diagnosis of its
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internal operations, and inform operations personnel of the status of the diagnostics.
The main target is to reduce the downtime by clearly locating the faults, which in
turn, permits quickly replacing the defective module. Any failures, faults predicted
failure conditions shall be annunciated to the operator. Examples of faults include:
 Processor fault
 Communication Link Faults
 Module Faults
 Input/Output Signal Faults
 Internal Memory Failures, etc.
 Cabinet Common Alarm
 Power Supply Faults.
 Over temperature monitoring
The faulty units shall be highlight edon LED’s located on each module and the fault
logged via the Sequence of Event lists through the communication link to the PLC.
Additional diagnostics of the input/output circuits by line monitoring shall also be
signaled by different colour LEDs. The alarms shall only be cleared after the faults
have been rectified. Transient (line monitoring, power supply, diagnosis, redundant
module, etc.) faults shall also be recorded and logged. Once the number of transient
faults has exceeded preset limit, the device shall be marked as faulty (if applicable).
In the event of failure of a redundant component, the faulty unit shall be marked as
‘failed’ and annunciated on the operator workstations. In the event that there is no
built-in redundancy, the fault shall be alarmed.
The system diagnostics shall support fault is location to a specific module or channel
or sub-system device, which can be subsequently removed and replaced.
The system diagnostics shall include both hardware and software diagnostics
routines which upon detecting an abnormal conditions, reports this information on
standard diagnostics displays and printers.
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Once a diagnostic test has detected a failure, a descriptive alarm shall be generated
and bumpless transfer to control to a redundant component shall be triggered
wherever specified.
6.3 Packaged Control System
The following equipments/subsystem shall be connected via Ethernet or serial link

RS-485 or fiber optic cable to the PCS:
 Automatic Tank Gauging
Serial interface shall be as much as possible utilized for monitoring purpose only.
Command through serial interface might be permitted for non-critical command only.
Local manual back-up shall be available for commands sent through serial interface.
Loss of serial communication shall not disturb normal operation of the plant.
Some subsystem might require redundant serial communication system. The PCS
shall have a standard feature to handle this redundant serial communication. Critical
command from or to packaged control system to safety system shall be through
hardwired interface.
7. OPERATOR INTERFACE REQUIREMENTS
The Operator Control Station shall be the primary operating center of the Terminal
Automation System (TAS). The OCS shall consolidate all information, provide status
and process control / safety system information, and information from serial interface
hub system (such as Automatic Tank Gauging, metering system, and batch
controller), sort and display data in a standardized format and enable operators to
execute control actions.
The Operator Control Station shall mainly consists of the following:
 1 unit of Supervisory Station (Engineering Work Station) with 21” LED Display.
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 2 units of OWS (Operation Work Station) with @ 21” LED Display.

 1 unit of PC Station with web server (TAS Admin Server) with 21” LED Display.
 1 unit of History Server.
 2 units of Color Laser Printer.
 1 units of Dot Matrix Printer.
Additional engineering station/laptop shall be supplied when necessary for the safety
system. Each server and stations shall be completed with 19" TFT color display,
keyboards, and pointing device/mouse. Necessary back-up/storage facility such as
DVD R/W drive shall be provided in the engineering stations and servers. The
system shall be able to do the following main function :
 initiate and stop sequences/programs

 adjust controller set-points, analogue output signals, change of control mode
(auto/manual/cascade)
 start and stop motors or actuators, open and close valve
 initiate and silence audible alarm
 acknowledge any alarm shown on mimics, alarm summary
 Acquire and display the information/data in real time
 Export information into spreadsheet and chart format
 Process variable value shall be instantaneously retrieved and stored (in 250
msec maximum)
 Store process variable for at least 72 hours
 Print the information when required
 Monitor the Fire detection system Reset of Flame detectors and ESD system
after shutdown.
Various access level shall be provided on the operator control station such as view
only, operator access, supervisor access, engineering access, and system
administrator access.
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Operator graphics shall be provided to display data in a user friendly and structured
format The display principles (windowing, special displays, etc.) shall be fully
described by VENDOR. These displays shall enable the operator to select and view
process variables, alarms, trends, status and graphic information. Displays
assignment for Operator Control Stations shall be defined and agreed during system
development by COMPANY and CONTRACTOR.
The control system shall be able to generate periodically or on demand shift reports,
transaction reports and maintenance reports. These reports shall be made from
current and archived data on a separate PC through MICROSOFT EXCEL files. The
required reports shall be easily formatted and configured using standard software
packages and shall not require any additional specialized programming.
7.1 ENGINEERING WORKSTATION

VENDOR would provide Engineering Work Stations (EWS) and install them in the
Control Room, refer to network architecture drawing. The EWS shall be able to cover
of DCS or PLC for PCS system. A portable workstation shall be provided for
configuration, tuning,trouble shooting and other maintenance functions. This shall
interface with the plantdatacommunications network for on-line programming,
configuration, trouble shooting, etc.
The workstation shall have interface capabilities to a printer or plotter via an RS 232
C or parallel port. The workstation shall have the capability for documenting software
programs, configuration, data bases, etc.
The workstation shall include, but shall not be limited to, the following minimum
hardware and software requirements:
 Microprocessor: Intel® Xeon Processor E5504. 2.00 GHz 4MB/800 QC

Minimum
 Memory: 8 GB DDR3 minimum
 Hard disk drive 2 TB minimum
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 Video-card 16 GB minimum
 CD-RW/DVD-RW drive
 Real time clock
 Minimum 25" LED color monitor
 QWERTY keyboard
 Mouse and Touch-pad
 Serial port
 Parallel port
 Ethernet port
 Power
 Voltage Input : Auto-ranging, 90 to 263 Volts @47-63 Hz
 Accessories : Surge Arrester
 USB ports, minimum
 Operating System: Microsoft Windows 7
 Anti-virus software
 An easy-to-use cursor device like mouse or trackball
 Latest anti-virus for Windows operating system
All operating software shall be compatible with the main operator / engineer console
software. It shall be possible to develop control strategies in an offline, separate
control
file and download them to the relevant PCS microprocessor module for
implementation,
Access to this unit should be restricted by key lock for use by authorized personnel
only.
7.2 Operator Work Station (OWS)

The Human Machine Interface (HMI) shall be provided. The HMI shall be utilized as
Operator/Maintenance Interface, with server capabilities.Minimum specification of
Man Machine Interface shall be as follow or better:
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Minimum
 Real time clock
 QWERTY keyboard
 Serial port
 Parallel port
 Ethernet port
 Power
 Human Machine Interface Software (latest available version)
 SQL server historian and reporting software
The MML (Main Machine Language) SQL server and reporting software shall be 1
(one) manufacturer. To avoid program crashing, the additional programming scripts
to create reporting shall be not permitted. The reporting software shall be support
X/Y scatter chart to improve analysis of process parameter including the ability to
define target regions for the automatic highlighting of process excursion.
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All process data parameter shall save in operator work station by SQL server
historian software. The SQL server historian shall provide data for reporting
software at work station and engineering Station.
CONTRACTOR shall provide un-authorized people protection to access the CW-

RW/DVD Drive, USB ports.
The HMI shall be provided with:
 Dynamic graphics displays (interface shall support ON/OFF status and digitally
coded analogue values)
 Continuous updating of data (data transfer from PLC to display shall not exceed
1 second)
 Alarm management (display and acknowledgement) for system application
software's being able to identify different alarm levels (eight levels as minimum),
The system shall handle all the process and system alarms. The system alarms
shall covers hardware and software alarms of all connected sub-system. There
shall be no effect on control function even during large number of incoming
alarms.
 Screen builder to generate graphic screens (process symbol, bar and line graph,
and associated attributes (colour, discrepancy)
 Display of SER (Sequence Event Recorder) data, control loops, first fault,
 Data logging and trend data functions,
 Time clock and calendar,
 Self-diagnostics feature,
Note: Password access shall be provided for different using levels (configurations,
programming, operation and maintenance.
The display on HMI shall be designed:
 To facilitate operator's activities, particularly in case of emergency,

 To respond efficiently and quickly to any incident.
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The HMI shall be provided with memory (screens, program) and its complete
software package (operating system, anti-virus, etc.) and all necessary cables.
The associated communication link with PLC system shall be carefully designed.
The protocol used between PLC and Operator Interface Console shall be
Ethernet/Modbus or dedicated interface operating network. CONTRACTOR shall
indicate his capability for such protocol.
Dialogue between PLC and HMI should restart automatically after a power supply
restoration.The HMI shall provide specific display for each location.
7.3 Server
Minimum specification for Server shall be follow or better :

Minimum
 Real time clock
 QWERTY keyboard
 Serial port
 Parallel port
 Ethernet port
 Power
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 Human Machine Interface Software (latest available version)
 SQL server historian and reporting software
8. ALARM MANAGEMENT
The system shall sequence the alarm according to ISA standard code S18.1
"Annunciator sequences and Specifications".
Alarm shall be detected by the system and processed to notify the operator through
operator station display and audible tone.
An alarm summary display shall be provided to show the operator a listing of alarms
status. Alarm shall be time stamped and shall appear in chronological order. Alarm
summary shall indicate the tag number and the description of each abnormal
condition in addition to "acknowledged / or not" status field.
An alarm log shall be stored and shall record the alarms in a chronological order. The
first-idfirst-out log sequence may be used for off line failure analysis. The Control
System shall be capable of storing at least a minimum of 1000 active alarms.
9. INSPECTION AND TESTING
Employer, at its option and with prior notification, shall be permitted free access to
Vendor's facilities during all phases of the work for performing visual inspections and
for routine monitoring and checking of documentation and work progress.
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Vendor shall notify Employer at least 14 (fourteen) working days in advance of

starting any shop tests.
Equipment tests, including heat soak test, shall be carried out as specified on the
Inspection and Testing Requirement Sheets, which will be attached to the PCS and
SCS requisition, and in accordance with the applicable sections of the referenced
specification and standards. Criteria for acceptance of tests shall be as established in
the attached or referenced specifications and standards.
Following the System Readiness Review, the system shall be prepared for the heat
soak test, and the Factory Acceptance Test (FAT) at the Vendor's (System
Integrator) staging facility.
The Vendor shall perform a heat soak test for the PCS/SCS System. The Vendor
shall raise the temperature surrounding each system to 120 °F (105 °F for work
station) at 80% humidity and maintain the temperature for 72 hours.
The ambient temperature surrounding the equipment and the maximum

temperatures within the equipment shall be continuously recorded during the heat
soak by the Vendor. All interconnecting cables shall be connected and the system
fully powered (including consoles, work station system cabinets with all printer circuit
cards).
During the heat soak, the Vendor shall utilize the keyboard to call up displays, status
tables, summary tables, etc., on a regular basis. Selected input/outputs shall be
simulated and recorded by the Vendor.
A proposed test procedure shall be submitted by Vendor for approval one (1) month
prior to the Factory Acceptance Test (FAT). Vendor shall prepare a detailed Factory
Acceptance Test procedure for approval by CLIENT. This document shall include
Vendor's and sub-system vendor's key personnel to be involved in the Factory
Acceptance Test and the testing responsibilities assigned to each party. Upon
approval by CLIENT or an authorized representative, this document shall establish
the basis for conducting the Factory Acceptance Test and shall include, but not be
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limited to, the tests described in this section. The FAT procedure list shall have one
column for Vendor's pre-FAT responsible staff signature. The pre-FAT must be
completed before notification to Employer for FAT witness.
The purpose of this testing shall be to witness Vendor performance of FAT and verify
the operation of hardware, the validity of programs, operator interface, guaranteed
accuracy and the proper functioning of components as a System, in accordance with
this specification prior to system shipment. Employer or its authorized representative
will take an active role in the Factory Acceptance Test. "Hands On" (with Vendor's
observation and advice) shall be permitted in the Factory Acceptance Test by
Employer or its authorized representatives. Sufficient time shall be allocated to
complete the Factory Acceptance Test, correct the errors detected, and retest the
system without jeopardizing the scheduled shipment dates.
As a minimum, the following tests shall be included in the FAT:
a. All system functions including service functions demonstration

b. All supplied diagnostic equipment
c. Complete system reloads
d. Power failures and restarts
e. Overload test
f. Electrical insulation tests
g. Failure diagnostic, automatic back-up and recovery for all redundant devices
h. Accuracy and operation of all I/O cards
i. Input and output from terminals to the different displays by simulating an input or
an output (100%)
j. All typical type of loops tested 100%
k. All complex loops (two or more variables linked together), tested 100%
l. All display pages available on the HMI work stations, tested 100%
m. Printer functions, tested 100%
n. Application software, tested 100%
o. For standard software packages, 100% functional check
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p. Real time reports generation, tested 100%

q. Test of PLC external communications (100%) with equipment supplied by Vendor
(TMR or high integrity safety PLC, Remote I/O Boxes)
r. Test of communication with TMR or high integrity safety PLC and F&G system
(100%). TMR or high integrity safety PLC and F&G shall be integrated as a whole
to PLC system at Vendor's workshop
s. Test of communication with other system package PLC, simulation system,
addressable unit. Vendor shall put forward for providing a simulator (similar
equipment that those provided) of all equipment which cannot be assembled at
the PLC supplier's workshop. Complete system test shall be carried out as far as
possible, on the premises.
Factory floor space, telephone, fax machine, test equipment, 100% simulation panel
(with lights and switches), man-hours, and any support required for successful
completion of the factory acceptance tests shall be provided by Vendor as part of the
Purchase Order price. The test equipment shall include a "purpose builts" simulation
test panel, one switch per discrete input, one potential meter per analogue input, one
LED per discrete output, and one millimeter output wired to the marshalling panel
and terminal panels for use during the pre-FAT and FAT test.
A pre-FAT test must be conducted by Vendor's test crew. The pre-FAT shall be
properly signed, item-by-item, in one column of the FAT procedure list.
Vendor shall keep accurate records of the hardware and software deficiencies,
errors, and action items encountered during each test, which shall be provided to
Employer or its authorized representatives. These deficiencies / errors / action items
shall be reviewed with Employer or its authorized representatives at the end of each
day to discuss the proposed procedures and schedule for correcting these items.
Employer or authorized representative may require the suspension of the FAT until
any such discrepancy has been corrected. After the discrepancy has been corrected,
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Vendor shall repeat the procedure or perform any other testing required to verify
correct operation of the system and that the discrepancy has been corrected.
10. DOCUMENTATION
Minimum documentation must include for all hardware, some major software and
user manual should be provided for final approval by the Contractor/Employer less
than 30 (thirty) days prior to the FAT.
Vendor should be provided a manual for the PLC system that includes all the
essential documentation for the installation, operation, facilities for maintenance and
functions of the system. This manual also should include the following aspects:
1. Description of the philosophy of all the hardware and software with configuration
of the system and drawing. It should be include all the main philosophies such as
redundancy, grouping system, bypass philosophy, configuration base, security
levels, etc. It also should include detail description of the specific strategies
complex systems which used.
2. General instructions and procedures start-up for the system which supply.
3. Manual hardware installation including outline dimensions, equipment

specifications, mounting details, power, signal and grounding connection details,
weight, heat load, and electrical requirements for all equipment.
4. Maintenance manual include :
 Theory of operation.
 All major schematic.
 Maintenance instructions for troubleshooting, routine adjustment, preventive
maintenance procedures, assembly and disassembly instructions, testing
procedures online and offline, and all the information needed for the
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installation of the system.
5. Operating instructions and equipment manuals for all components.
6. Configuration instructions which includes standard configuration for all I/O,

control, logic and display.
7. Manual technical description of hardware.
In addition to the information provided by Employer, Vendor shall provide all

necessary documentation for the development and implementation of programs.
Minimum documentation :
 “Fill in the blank” type programming sheet
 CD–ROM Program
 Listing Program
Vendor shall prepare all “as built” drawings Vendor after SAT.
Two sets of CD-ROMs and software must be provided for the final drawing.
11. TRAINING
11.1 Scope
Contractor should be ensure that the Vendor provides for the training of Employer
personnel in all aspects of control systems including theory of operation, system
architectural, implementation of system configuration, maintenance and daily
operation of equipment. Three different levels of training classes must be done to
meet the levels of operations personnel and engineering.
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Vendor shall be responsible for providing all equipment, computer station and
equipment used in a professional learning environment.
11.2 OperatorTraining
Operator training classes to be held at the site, at the time of plant commissioning
activities will be carried out, to familiarize personnel with all aspects of the
operational plant control system.
Training should be done a minimum of three (3) days for field personnel.
11.3 Instrument Technician Training
Technician training class must be implemented at the site, at the time of plant
commissioning activities will be carried out, to train technician personnel in all
aspects of the theory, operation and configuration of the system and logic
implementation. Performed at a high environmental engineering from the course at
least 50 % of the time this course configuration work to be done by the instructor,
demonstrations, tutorials and troubleshooting. This course must be run for at least
five (5) days.
11.4 Engineer and Supervisor Training
Engineer and supervisor training class should be implemented in the Vendor place to
provide an overview of all aspects of the theory, operation and configuration of the
system and logic implementation. Time course of configuration work to be done by
the instructor demonstrations tutorials and troubleshooting. This course must be run
for at least five (5) days.
12. PREPARATION FOR SHIPMENT
PCS and SCS shall be cleaned and inspected prior to packing for shipment in order
to remove accumulated water, dust and manufacturing debris. The system shall be
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packed in moisture proof containers and shall be able to withstand storage conditions
of a temperature range of 0 to 140°F and a relative humidity of 5 to 95% non-
condensing for up to five (5) years.
PCS and SCS shall not be released for shipment until all test data is approved by
Employer.
PCS and SCS equipment shall be packed in accordance with the best industrial
practice for electronic equipment to avoid damage due to rough handling. The
following are the basic requirements, but are not limited to:
a. Vendor shall identify desiccants and inhibitors used and the required
replacement frequency.
b. Items not immediately packaged after manufacture shall be protected from

contamination.
c. Keys, disks, cartridges, special tools shall be individually packaged and clearly
identified on the outside of the package.
d. Equipment shall be properly protected against shock, vibration and

environmental conditions. Items subject to corrosion shall be suitably protected.
e. Lifting points shall be clearly marked. Where special blocking, anchoring, or

cushioning is necessary, the essential details shall be submitted to Employer or
an authorized representative for review.
f. The outermost covering shall be clearly marked with the complete Vendor
identification and shall include the weight. Employer's or an authorized
representative's equipment numbers shall also be marked.
g. Written instructions covering the location and stacking limits of the crates or
boxes on the transport vehicle shall be specified. These shall be marked on the
container.
h. Cabinet shall be self-supporting. The centre of gravity and lifting points for large
and heavy equipment shall also be identified.
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i. Employer or an authorized representative reserves the right to inspect the

equipment prior to shipment. Vendor shall notify Employer or an authorized
representative of each shipment no less than 15 days prior to the date of
shipment to allow Employer to review and inspect.
A packing list shall be placed both on the inside and outside of each individual
package or container. Packing lists itemizing contents of each box crate shall be
placed inside each shipping unit. A second copy, together with any special
instructions, must be sealed in a waterproof envelope and securely fastened to the
outside of each shipping unit. Packing lists shall state purchase order number, item
number and full description of contents.
Openings or other components subject to mechanical damage or corrosion shall be

protected. Protection shall consist of plastic or wood covers, sealing with waterproof
tape, or enclosing in temporary housing. The shipped loose items shall be crate in
waterproof boxes.
Vendor shall be responsible for load out, tie down and securing for shipment of the
completed assemblies on Vendor-furnished transport. Vendor shall be responsible
for supplying any required equipment or frames and required rigging for the load-out
at Vendor's facility.
Vendor shall be responsible for transport to Employer's designated receiving

location. Removal from transport upon arrival at designated receiving location shall
be by Employer or designated agent.
13. QUALITY ASSURANCE SYSTEM
13.1 General
Vendor shall submit project Quality Plans to the Employer after award of purchase
order. This Quality Plan shall incorporate specific quality requirements of the
Employer. Along with this document, Vendor shall also submit an established and
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documented Quality System in accordance with ISO 9001/9002 or Employer

approved equivalent.
Vendor shall maintain they Quality Assurance system throughout the Purchase Order
period.
The full extent of these requirements shall be applied to the sub-Vendor's who get
subcontracts the whole or main parts of the work or materials. Surveillance/audit of
Vendor shall be performed by the Vendor as necessary.
Control of sub-Vendor shall encompass measures to verify that progress and quality
of works meet all the requirements.
13.2 Quality Audits
a. General
Employer may conduct quality audits, technical reviews, test witnesses and
inspections at source in order to verify compliance with the Purchase Order
requirement.
Vendor shall provide free access to the Employer or its delegated inspector and
cooperate with the Employer or its delegated inspector in the performance of all
testing, witnessing and audits.
b. Audits/Reviews
The Employer reserves the right to audit at source at any time during the duration
of the Purchase Order and will give two (2) week’s notice. Vendor shall undertake
to close out any findings raised as part of such an audit.
Vendor shall co-operate in the provision of information and the supply of all
necessary Vendor/sub-Vendor's personnel to allow the Employer or delegated
inspector to perform a meaning audit/review.
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The results of any internal audits/reviews conducted by Vendor and sub-

Vendor'sshall be documented and made available to the Employer within two
weeks after completion of Vendor/sub-Vendor's audit/review.
14. WARRANTY/GUARANTEE
The Vendor shall design the equipment for twenty (20) years design life cycle and
warrant the availability of spares and service for all parts for a minimum of two (2)
years.
Material and equipment shall be warranted/guaranteed by Vendor/Manufacturer to

perform in accordance with specification requirements and to be free of defects and
poor workmanship including, but not limited to, those caused by inadequate
preparation for shipment for a period of one (1) year after material and equipment is
placed in service, but not exceeding eighteen (18) months following delivery to the
contracted destination.
Vendor shall repair or replace all defective items during the guarantee period at no
cost to Employer.

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JASA KONSULTASI

PROCESS CONTROL SYSTEM SPECIFICATION

Contract No : HK.0502/296.1/P.III- Page 1 of 40

EMPLOYER : PT. PELABUHAN INDONESIA III (PERSERO)

JASA KONSULTASI PERENCANAAN PEKERJAAN

CONTRACT NO. : HK.0502/296.1/P.III-2016

0 08/08/2016 Issued For Bid ND DW BA

REV PRP'D CHK'D APV'D

PROCESS CONTROL SYSTEM SPECIFICATION

Contract No : HK.0502/296.1/P.III- Page 2 of 40

REVISION HISTORICAL SHEET

Rev. Date Page Description

0 08/08/2016 All New doc

PROCESS CONTROL SYSTEM SPECIFICATION

Contract No : HK.0502/296.1/P.III- Page 3 of 40

PROCESS CONTROL SYSTEM SPECIFICATION

Contract No : HK.0502/296.1/P.III- Page 4 of 40

6.1.1. Communication Network Interface................................................................................21

PROCESS CONTROL SYSTEM SPECIFICATION

Contract No : HK.0502/296.1/P.III- Page 5 of 40

This development of Storage Tank will be equipped with Integrated Monitoring

PROCESS CONTROL SYSTEM SPECIFICATION

Contract No : HK.0502/296.1/P.III- Page 6 of 40

3. CODE, STANDARD & REFERENCE

 API RP 551 : Process Measurement Instrumentation

PROCESS CONTROL SYSTEM SPECIFICATION

Contract No : HK.0502/296.1/P.III- Page 7 of 40

 ISA 5.3 : Graphic Symbols for Distributed Controls

4. PROCESS CONTROL AND SAFETY SYSTEM GENERAL DESIGN

3.1 System Recovery

PROCESS CONTROL SYSTEM SPECIFICATION

Contract No : HK.0502/296.1/P.III- Page 8 of 40

System design shall incorporate a comprehensive set of diagnostic features including

No spurious plant or process equipment shutdowns shall be initiated during any

3.3 Modularity and Standardization

PROCESS CONTROL SYSTEM SPECIFICATION

Contract No : HK.0502/296.1/P.III- Page 9 of 40

3.4 Electrical Transients, Electro Magnetical Interferece, and Radio Frequency

3.5 System Control Panel

Spare terminal shall be provided 20 percent of spare I/O.

PROCESS CONTROL SYSTEM SPECIFICATION

Contract No : HK.0502/296.1/P.III- Page 10 of 40

4. PROCESS CONTROL SYSTEM

4.1 PCS Functional Requirement

Controller shall be also capable to provide auxiliary function like multiplication,

PROCESS CONTROL SYSTEM SPECIFICATION

Contract No : HK.0502/296.1/P.III- Page 11 of 40

4.2 PCS Hardware Requirement

4.2.2 PCS Controller Unit

Controllers units shall be based on latest version of microprocessors capable of

PROCESS CONTROL SYSTEM SPECIFICATION

Contract No : HK.0502/296.1/P.III- Page 12 of 40

4.2.3 I/O Modules

Input/output modules shall be replaceable without removing the signal wiring

Analogue input modules shall have transmitter out-of-range fault detection, as

PROCESS CONTROL SYSTEM SPECIFICATION

Contract No : HK.0502/296.1/P.III- Page 13 of 40

Different types of digital outputs shall be required to enable control to actuating

The contact outputs shall be configurable to allow for :

 maintained, latching, pulse contact

4.3 PCS Software Requirement

Standard operating system software, with full documentation, shall be provided by

The following control and calculation algorithms shall be provided, as a minimum: