QDR-GCS-ESJ-REP-1000 RevA

OWNER PMC OIL & GAS DEVELOPMENT COMPANY LTD CONTRACTOR
QADIRPUR COMPRESSION PROJECT

INSTRUMENTATION AND CONTROL
Document Title:
PHILOSOPHY
Date: 8-Feb-07 Document No: QDR-GCS-ESJ-REP-1000 Rev: A Class: 3 Sheet 1 of 31

PHILOSOPHY
TABLE OF CONTENTS
A Issued For Review 8-Feb-2007 LY QBP LSH
Rev Description Date Prepared Checked Approved Client

1INTRODUCTION..................................................................................................... ...........................5

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1.1 Process Description.............................................................................................................................. ......5

2SCOPE........................................................................................................................... ....................5
3ENVIRONMENTAL CONDITIONS................................................................................................ ......6
4ABBREVIATIONS AND DEFINITIONS................................................................ ..............................6
5CODES AND STANDARDS.................................................................................. .............................7
6UNITS OF MEASUREMENT AND SCALES............................................................ ..........................7
7REFERENCED DOCUMENTS................................................................................... ........................8
8STATION CONTROL SYSTEM........................................................................... ...............................8
1.2 General Information and Description........................................................................................ ..................8
1.3 System Architecture Overview.......................................................................................................... ..........9
1.4 Software Architecture.............................................................................................................................. ..10
1.5 Networking and Communication............................................................................................. ..................11
1.6 Operating Modes.............................................................................................................. ........................11
1.7 System Security and Access Levels....................................................................................... ..................12
1.8 Auto Diagnostics............................................................................................................................ ...........12
1.9 Expandability/Spares................................................................................................................... .............12
1.10 System Power......................................................................................................................................... 13
9FIELD INSTRUMENTS.............................................................................................................. .......13
1.11 General Information and Description............................................................................ ..........................13
1.12 Environmental Protection.................................................................................................................... ....14
1.13 Explosive Hazard Protection.............................................................................................................. .....14
1.14 Instrument Type and Signal level.................................................................................................... ........14
1.15 Safety related instrument loops........................................................................................ ......................14
1.16 Field Communication................................................................................................................. .............15
1.17 Power Supply............................................................................................................. ............................15
1.18 Instrument Installation........................................................................................................................... ..15
1.19 Air Supply Requirements.................................................................................................... ....................16
1.20 Instrument cables and wiring.................................................................................................. ................16
1.21 Marshalling and Junction Boxes............................................................................................ .................17
1.22 Earthing and Grounding....................................................................................................................... ...17
10FIRE & GAS DETECTION SYSTEM....................................................................... .......................17
1.23 Requirements................................................................................................................... ......................17
1.24 System Configuration.................................................................................................... .........................18
1.25 Voting and Redundancy....................................................................................................................... ...18
1.26 Interfaces...................................................................................................................................... ..........19

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1.27 Fire and Explosion Hazard Management............................................................................................. ...19

11EMERGENCY SHUTDOWN (ESD) SYSTEM.................................................................... .............20
1.28 General Requirement.................................................................................................... .........................20
1.29 ESD & MOS Operator Console............................................................................................................... 21
1.30 Redundancy................................................................................................................ ...........................21
1.31 Interface to other systems............................................................................................ ..........................22
1.32 Fault Monitoring & Testing............................................................................................... .......................22
1.33 Sequence of Events.............................................................................................................................. ..22
1.34 First out Alarm............................................................................................................ ............................22
1.35 Start-up override......................................................................................................................... ............22
1.36 Initiating Devices.................................................................................................................................... .23
1.37 Final Actuators............................................................................................................................ ...........23
1.38 Depressurizing Valves...................................................................................................... .....................24
1.39 Cables.......................................................................................................................... .........................24
1.40 Operation of ESD Valves...................................................................................................... .................24
11.1.1 Valve to fail safe position................................................................................................................ .24
11.1.2 Valve return to normal position..................................................................................................... ...24
1.41 Valve return in control............................................................................................................ ................25
1.42 Limit switch on valves.............................................................................................................. ..............25
12ALARM SYSTEM.................................................................................................... .......................25
1.43 Configuration.................................................................................................................... ......................25
1.44 ALARM MANAGEMENT................................................................................................................ .........25
12.1.1 General................................................................................................................................... ........25
12.1.2 Alarm Banner........................................................................................................................ ..........26
12.1.3 Alarm & Event Loggers...................................................................................................... .............26
12.1.4 Alarm Priority............................................................................................................. .....................27
12.1.5 Alarm Types......................................................................................................................... ...........28
12.1.6 Alarm Grouping & Hierarchies................................................................................... .....................28
12.1.7 Alarm Cycle & Animation....................................................................................... .........................28
12.1.8 Operator Action Journal..................................................................................................... .............29
12.1.9 Alarm & Event Printing............................................................................................................. .......29
1.45 BYPASS MANAGEMENT............................................................................................................ ...........29
12.1.10 Bypass General Requirements.......................................................................................... ...........29
12.1.11 Maintenance Override Switches........................................................................... ........................30
1.46 DOCUMENTATION.................................................................................................... ............................30

Document Title:
PHILOSOPHY

Document Title:
PHILOSOPHY
1 INTRODUCTION
The Oil & Gas Development Company Limited (OGDCL) is operator of Qadirpur Gas Field,
situated in Sindh Province in Central Indus Basin.
COMPANY plans to install a new Gas Turbine Driven Compressor Station at the existing Qadirpur
Gas Treatment Plant and to extend the gas gathering system to enhance the raw gas production
and maintain a high production plateau.
This report is part of the detailed design dossier describing the technical philosophy.
1.1 Process Description
The compression process consists of inlet separators, turbine compressor units, gas coolers and
sales gas output metering skids.
The capacity of the process will change gradually, and the compressor station needs to cover a
wide variety of operation conditions. The operation life of the compressor station consists of the
following two phases:
 Phase A – Operation at constant flow rate
The flow rate of 730 MMSCFD causes a decrease in gas field pressure from 815 psia
(56.2 bara) to 215 psia (14.8 bara).
 Phase B – Operation at constant inlet pressure
After obtaining a pressure of 215 psia (14.8 bara), the compressor station is operated at
constant inlet pressure, which causes a decrease in flow rate from 730 MMSCFD to 179
MMSCFD.
The outlet pressure maintains constant at 895 psia (61.7 bara) over the total operation life.
Six turbine compressor units will be installed to cover the complete operation range. Three
compressors will be equipped with high pressure bundles and three with low pressure bundles.
At the end of the process, pressed gas will be delivered to the gas treatment plant and Liberty
Power Ltd. through two metering devices respectively.
2 SCOPE
The purpose of this document is to present an overall description and to provide general

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guidelines for the engineering design documents for the instrumentation and control system of the
compression station.
3 ENVIRONMENTAL CONDITIONS
- Temperature Max 50 °C (122 °F)

Min 3 °C (17 °F)
- Absolute max/min recorded Max/Min 53 / -1.1 C
- Average Monthly Relative Humidity Max 77%
Min 20%
- Max/Min Barometric Pressure 1010.5 / 985.7 mbar
- Altitude reference 68 m
- Maximum daily rainfall (24 hours) 185 mm
- Maximum wind velocity 51 mph (82 km/h)
4 ABBREVIATIONS AND DEFINITIONS
COMPANY Oil & Gas Development COMPANY Limited (OGDCL)

EPCC/LSTK Engineering, Procurement, Construction, Precommissioning,
Commissioning and 6 Month of Operation / Lump Sum Turn Key
CONTRACTOR China Petroleum Engineering Construction Co. (CPECC), Carrying Out
the EPCC/LSTK Works for the Project
SUB-CONTRACTOR A party which manufactures and/or supplies equipment, technical
documents/drawings and services to perform the duties specified by the
COMPANY/CONTRACTOR
PROJECT Qadirpur Compression Project
The word shall is a verbal form used to indicate requirements to be strictly followed in order to
conform to this specification and from which no deviation is permitted, unless accepted by all
involved parties.
The word should is a verbal form used to indicate that among several possibilities one is
recommended as particularly suitable, without mentioning or excluding others, or that a certain
course of action is preferred but not necessarily required.
The word may is a verbal form used to indicate a course of action permissible within the limits of
this specification.
The word can is a verbal form used for statements of possibility and capability, whether material,

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physical or casual.
SCS – Station Control System

SOE – Sequence Of Event
MOS – Manual Operating Station
I/P – Current Pneumatic Convertor
PIP – Picture In Picture
HMI – Human Machine Interface
5 CODES AND STANDARDS
The following codes, regulation and standards of the latest editions SHALL be used where
applicable. Where any conflict exists between the referenced codes or standards, the most
stringent of the codes or standards SHALL prevail.
API American Petroleum Industry Standards
EN European Standard
CE Declaration of Conformity to European Standards
ISA Instrument Society of America
DIN Deutsche Industrie Normen (German Industrial Standard)
IEC International Electro-technical Commission
6 UNITS OF MEASUREMENT AND SCALES
Imperial Unit System shall be used for most of the measurements and scales, apart from a couple
of SI Units.
Vapour flow ft3/h, MMscfd Mass Flow lb/h
Pipe diameter in Volume Flow bpd/gpm
Heat Duty MMBtu/h Molar Flow kmol/s
Specific Heat kJ/kg Density lb/ft3
Heat Transfer Btu/hft°F Viscosity cP, cS
Temperature °F Voltage V
Length km, m, mm Current A


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Mass lb Power kW, MW
Time s, h, d, a Rotation rpm
Pressure psig, psia Noise dB(A)
7 REFERENCED DOCUMENTS
QDR-GCS-ESJ-SPC-1001 Specification for Station Control System

QDR-GCS-ESJ-SPC-1000 General Specification for Design, Fabrication, Installation of
Instrument
QDR-GCS-ESJ-SPC-1006 Specification for Instrument Cable
QDR-GCS-ESJ-SPC-1008 Specification for Fire & Gas Detection, Inert Gas Extinguishing
Specification
QDR-GCS-ESJ-SPC-1009 Specification for Machine Monitoring System
QDR-GCS-ESJ-SPC-1004 Specification for Programmable Logic Controller
QDR-GCS-ESJ-SPC-1005 Specification for Cabinets
QDR-GCS-ENG-REP-1003 Tag Numbering System
8 STATION CONTROL SYSTEM
1.2 General Information and Description
The compression station will be provided with a Station Control System (SCS) for monitoring and
controlling of new designed facilities of the Qadirpur Compression project to maintain the station
smooth operation and safety. The new Compressor Station and all auxiliaries are designed as a
complete independent and stand alone system with autonomous control system. The SCS
comprises process monitoring system, emergency shutdown system and fire & gas detection
system.
In the selection and design of the station monitoring and control system and devices, priority is
given to:
 performance
 reliability and safety
 simplicity
 maintainability
 single point or single loop effected failure


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 support of advanced diagnostic and quality assurance goals
The station control system is expected to perform data acquisition, data processing, data storage,
process trend, diagnosis, display, alarm, print, as well as basic control functions such as PID,
sequence, logic interlock, etc.
The Station control system is expected to include Asset Integrated Management System (AIMS).
The station control system is expected to receive signals of analog, Pt100, discrete and to drive I/P
control valves and solenoids.
The station control system is expected to communicate with other systems by using Ethernet with
TCP/IP protocol, e.g. the DCS at gas treatment plant, PLC stations.
1.3 System Architecture Overview
The envisaged station monitoring and control system architecture is fully distributed in plant and/or
within the control room environment, allowing for true peer-to-peer communication over redundant
system data communication highways.
A general overview of the distributed control system architecture is given in Control System Block
Diagram (QDR-GCS-ESJ-DRG-1001). The block diagram clarifies the design intent, assists in
ensuring that integrated, unified and fully functional design is proposed.
The system uses three main layers in control structure:
1) Supervisory Control and Operator Interface Layer
This layer provides human-machine interface (HMI) and full functionality for operator control and
monitoring. The main components are as follows:
2x Operator workstations
1x Engineering workstation
1x Sinoptic Screen
1x Operator console for Engine Unit Control
4x Printer (2 line printers for events and alarms, 2 laser jet printers)
2) Autonomous control, Data Processing and Process Interlock Layer
The major role of the layer is to collect updated data from data files, process data under

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autonomous control logic and interlock condition and provide them to the real-time database. The
main Components are as follows:
Station Control System (PLC based)
F&G Alarm System
ESD System
UCS #1 through UCS #6
1x Communication Interface
2x Data Servers
3) Data Acquisition Layer
The major roles of the layer are to receive, transmit and store data from and to process control
system, F&G system, ESD system, as well as individual instruments and devices to the
designated data files by relevant I/O channels. Other important roles are to monitor any
malfunction of the connected devices and provide emergency cures if possible as well as to report
status to the control centre. The main Components are as follows:
System I/O channels
Unit control I/O channels
Remote I/O channels
1.4 Software Architecture
The operating system is windows.
The control functions are based on multi-tasking SW application and real-time database (RTDB)
located on redundant configuration of two Data servers. Servers are responsible for data
acquisition and handling on set of parameters such as polling controllers, alarm checking,
calculation, logging and archiving.
HMI Operator interface is the means by which the operator performs his tasks. HMI is fully graphic
environment, dynamic parameter display and easy for system navigation.

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1.5 Networking and Communication
The SCS shall also receive information from other self-contained autonomous systems (e.g. unit
control system), Subsystems, remote I/O modules and Field Instrumentation.
A general overview of field communication scheme is given in Control System Block Diagram
(QDR-GCS-ESJ-DRG-1001).
Network communication (LAN) Server, Client and Server, Server communication in redundant
Ethernet configuration is applied for main data exchange, standardized and advanced application
connectivity, by using TCP/IP networking protocol.
The interface with PLCs and instrumentation sub-systems uses standard communication links RS
485.
The SCS supports communication with smart transmitters in analogue (4-20mA) and digital
communication (HART protocol).
1.6 Operating Modes
The stations shall be operated in the modes as stated below. Considering the actual mode in
question, it has to be emphasized that commands generated by the Station ESD System shall be
effective in each mode.
 Remote Automatic Mode - This mode makes up the most frequently used mode. The
stations are under the automatic control at the control centre.
 Remote Manual Mode – This mode will be switched over to in case of shutdown, blow
down, or adjustment of certain parameters under human interference at the control
centre.
 Local Automatic Mode - This mode will come into use in cases of abnormal process
situations. The automatic operation mode will be maintained, however the set points
and commands will be given from the local HMI Sub-systems (Engine Unit Control,
MCC Control Unit, Auxiliary system Sub-control unit).
 Local Manual Mode - This mode will be applied in case of maintenance or the event of
severe malfunction of the station. All automatic functions are out of service and the
control of the process facilities will be executed manually.

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1.7 System Security and Access Levels
A security strategy for the SCS including access to controllers and control configuration is
incorporated to ensure subsequent safe and reliable operation. The system provides an access
control to the various facilities in secure manner by the key lock, badge reader or password.
 View Only - The process shall be capable of being monitored, but no data entry or
process changes shall be made.
 Operator Access - Changes required to effectively control the plant shall be permitted,
but changes to "sensitive" parameters such as tuning constants, process ranges, etc.
shall not be permitted.
 Engineer Access - All data base parameters, including sensitive parameters and full
functionality shall be available for off process configuration, point building, display
building, etc.
The security default level of access shall be defined on a per Operator Console basis, and shall be
changeable only by key switch selection of a higher access level.
1.8 Auto Diagnostics
The SCS provides self diagnostic routines that allow continuous on-line monitoring of the software
and hardware. The diagnostic functions shall run continuously and shall be capable of detecting a
fault before system integrity is lost. It shall inform the operator of a failure and indicate the type of
fault and the device unit or card to be replaced. The System is designed to provide maximum ease
of equipment servicing. Any special fixtures or software programs such as card extenders, test
circuit boards and off-line diagnostics software shall be provided along with the System. Each
system module shall contain appropriate levels of self test designed to ensure that the module is
capable of performing correctly prior to being placed in operation and to monitor its performance
while in operation. Failures shall be indicated by means of an LED(s) on each module and the
Operator Interface.
1.9 Expandability/Spares
The system shall be designed for maximum flexibility in expansion. It shall be possible to add I/O
and controllers to the exiting equipment, on-line and under full power, without impacting the
current system operation. The system shall also provide the capability to add nodes -- such as
consoles, interfaces, host computers, controllers, etc. to the existing data highway without

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affecting the current highway communications.
The System shall be provided with 20% spare capacity in hot running spare parts as part of the
system supply. The System shall provide the capability to replace a failed part with a spare, on-line
and under power without affecting the existing system operation.
1.10 System Power
The AC 230 V 50 Hz as main power supply and 24 V DC power supply system shall be designed
to meet the power requirements of the system and field instruments.
Fusing of individual circuit cards is mandatory. Analogue loop power shall be fused on an
individual point basis.
In addition, an integral uninterrupted operation of the CSC including equipment in control room
and field instruments is required for a minimum of 1 hour upon loss of utility power supply. This is
required to insure transient power surges and dips do not affect the operation of the system and
allow sufficient time to control the station go over the unsteady time or into safe status.
The system shall be capable of monitoring and reporting the status of AC power supplies and
battery back-up conditions to the operator.
9 FIELD INSTRUMENTS
1.11 General Information and Description
Instrumentation should be provided to satisfy the following requirements:
 Enable safe and convenient start up, uninterrupted operation and controlled shut down
 Enable safe manually initiated emergency shutdown from agreed locations. Different
levels of shutdown shall be provided.
 Provide automatic protective action where deviation of process variables could result
in hazard to personnel or equipment.
 Provide information and control to enable plant and utilities to meet specific
requirements for safety, efficiency and economic operation.
 Provide local indication of process variables at points allow local adjustment of control,
shutdown and operation under abnormal condition.

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 Suitable for reliable and continuous operation in the service conditions stated in the
specification for environmental and utility data.
 Identified by unique tag number by the loop as stated in Tag Numbering System
(QDR-GCS-ENG-REP-1003).
1.12 Environmental Protection
The minimum acceptable standard of protection against moisture or dust ingress for outdoor
mounted equipment shall be to IEC 60529 classifications IP65.
All outdoor mounted electronic instrumentation, including pressure transmitters, pressure,

switches, I/Ps, field signal indicators-LCD Displays, etc., as a minimum, shall be installed on
instrument protection holder with sunshade complete with hook-up.
1.13 Explosive Hazard Protection
All field instruments with electrical or electronic components shall be suitable for installation in the
defined hazardous area. All equipment shall be certified for the appropriate area classification, gas
group and temperature class. API RP 505 shall be complied with in area classification, and IEC
60079-14 shall be complied with in explosion proof class of instruments.
1.14 Instrument Type and Signal level
Instrumentation shall however possible be of electric/electronic and pneumatic type. Pneumatic

Instrumentation shall be used for valve actuators and purely local controls with remote set point or
override function if require.
Accuracy of the instrumentation and instrument loop shall be matched to the requirements of the
process and the relevant Control system function. For connection of the process values to the
Control system, electronic type instrumentation with incorporated local digital displays shall be
used. The following levels of field signals are preferred:
 Analog electronic signals: 4-20 mA, Pt100
 Analog Pneumatic signal: 0.2-1.0 Bar (3-15 psig)
 Discrete signal: 24V DC, voltage free contacts
1.15 Safety related instrument loops
To reduce probability of Station shut down due to single instrument failure, instruments which can

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trigger the emergency shut down have to be configured 2 out of 3. Also the instruments with safety
related function have to be voting system with configuration 2 out of 3.
1.16 Field Communication
Transmitters of the SMART type shall be used offering two types of communication, one with the
standard 4 to 20mA analogue signal and the other FSK Frequency Shift Keying (FSK) type digital
signal in HART Protocol superimposed on the analogue signal.
1.17 Power Supply
The power supply voltage level of 24 VDC is preferred for all instruments, and 230 VAC may only
be applied where necessary.
In order to ensure a safe operation and supervision of the system even in case of main power
failure, all instruments shall be powered by UPS/DC systems mentioned in 8.9.
1.18 Instrument Installation
All local instruments shall be accessible from grade or platform.
Piping isolation block valves shall be supplied for all pressure installations. An independent
process tapping with valve isolation shall be provided for each individual instrument. Five valve
manifolds shall be provided for all differential pressure transmitters, switches and gauges. Two
valve manifolds shall be provided for all pressure transmitters, switches and gauges.
Instrument impulse tubing (process connection) shall be 12mm OD x 1.5mm wall thickness
stainless steel as a minimum. Connections to instruments shall be ½” NPT or Instrument flange
connection.
Instrument pneumatic signal tubing shall be 6mm OD x 1.0mm wall thickness stainless steel as a
minimum. Air supply tubing between valve take off and filter regulator shall be 12mm OD x 1.5mm
wall thickness stainless steel as a minimum. Tubing between filter regulator and air user shall be 6
mm OD x 1.0 mm thickness stainless steel as a minimum. Connections to instruments shall be ¼”
NPT.
All instruments in the field area have to be mounted in suitable protective shelters and fixed on
mounting racks. Mounting and connection has to be performed in accordance with the typical
hook-ups and the requirements of the instrument SUBCONTRACTOR and have to take care for a
safe and hampering free operation of the instrument The protective shelters have to provide

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appropriate mechanical protection to all mounted instruments with it. Equipment designed for use
in the field, should be protected from direct sunlight and ambient temperature higher than
SUBCONTRACTOR’S maximum recommended temperature.
1.19 Air Supply Requirements
The air supply for individual instruments shall be taken off the top of the main header or an
auxiliary manifold supplied from the top of the main header. Each take off shall have an isolation
valve. Ten percent spare valves and capped take-offs shall be provided on a header or manifold,
with a minimum of two. Air quality shall meet the requirements of:
 Non lubricated Instrument air (maximum oily vapour condensable of 1ppm)
 Filtrated at 1-5 microns
 Dew point should be 10°C below the lowest expected ambient temperature
1.20 Instrument cables and wiring
All instrument cables and wiring shall be provided with core identification. All connections and
terminations shall be made on terminals. IS circuits and Non-IS circuits shall be run separately in
different cables. 24 VDC level signal conductors and 230 VAC level signal conductors shall be run
in different cables. Grouping for instrument signal category in cables shall be as follows:
 Electronic signals (4-20 mA), resistance thermometers, thermocouples.
 ESD Electronic signals (4-20 mA), resistance thermometers, thermocouples.
 Fire and gas signals
 IS electronic signals (4-20 mA), resistance thermometers, and thermocouples.
 IS ESD electronic signals (4-20 mA), resistance thermometers, and thermocouples.
 IS Fire and Gas signals
 Digital Communication
Only signals of the same signal and category shall be contained in the same multi-core cable. All
conductors forming part of intrinsically safe circuits shall be contained in multi-core cable reserved
solely for intrinsically safe circuits. Cable sheath for IS circuits shall be coloured blue (IEC 304).
Cable glands and cable fittings shall be suitable for the cable dimension, type and certified for

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hazardous areas where applicable.
Conductor shall be sized to provide a loop resistance within that required for the application. The
minimum conductor size shall be 0.5 mm2 for stranded cables and 1.0 mm2 for solid conductor.
Individual analog circuit cables should consist of twisted pair with tape screen. A multipair cable
should have a collective overall screen.
Cable installation is in such a way that it is protected and no subject to damage. However, in
location where cable may be subject to damage, they shall be protected by overall armour. Steel
wire armour is preferred.
1.21 Marshalling and Junction Boxes
Marshalling and Junction boxes for both shutdown and intrinsically safe circuits shall be separate
from those on general instrument measurement and control duty.
Separate junction boxes shall be used for essential, intrinsically safe, fire and gas, and normal
services. Junction boxes for use in hazardous area must be certified for that area, with a degree of
protection of IP65. Sufficient terminals shall be installed in junction box for terminating all cable
pairs/cores including spares and screens. In addition, minimum of 10% spare terminals shall be
provided. The junction box shall be equipped with bottom entry gland/continuity plates. All cables
shall enter via bottom plate.
1.22 Earthing and Grounding
Cable screens and spare wires shall be floated at the field end with continuity along the entire run
from field cables through trunk cables to cabinets by screen terminals or insulated earth bars
provided in junction boxes. Screens and spare wires shall be grounded at the marshalling panel by
means of a grounding bar. Intrinsically safe cables shall be grounded at barrier only. And the
earthing pole for shunt diode barriers shall be separately arranged.
10 FIRE & GAS DETECTION SYSTEM
1.23 Requirements
The Fire & Gas Detection System shall monitor plant operations and advise plant personnel in the
event of detection of fire or gas. The Fire & Gas detection system shall form integral part of the
Instrumentation and Control system. Basic requirements on the F&G detection system are:
 Detection fire/gas as early as possible


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 Personnel alert with audio-visual alarm
 Preventive actions to be taken at an early stage
 Initiation of appropriate shut down signals upon confirmed alarms
 Interlock with HVAC system
 Accident area recognition
The design of the F&G detection system shall follow the rules, recommendations, codes and
standards established by the NFPA.
The selection of fire/gas detectors for an area shall reflect the anticipated prime indication of a fire
o gas outflow. Heat, smoke and flame detectors shall be considered depending on the most
probable prime indication of fire of a particular site.
1.24 System Configuration
Main Components of proposal system are listed below:
 Fire Alarm System and Gas Alarm System Panel
 Automatic Detectors (smoke detectors, fire detectors, HSSD detectors)
 Manual Call Points (fire alarm push buttons in buildings and in the open area located
on free accessible escape way points)
 Audio-visual alarm devices (beacons and horns installed in buildings and outdoors)
1.25 Voting and Redundancy
1) Heat detectors
Heat detectors are considered high reliability devices and are not susceptible for spurious
activation. Therefore in special cases, activation of a single heat detector shall initiate an alarm
and if required, an executive action without a need for redundancy.
2) Smoke and Flame detectors
Smoke and flame detectors have a lower reliability than heat detectors and are prone to spurious
activation. Therefore for facilities, which require executive action on detection of fire/smoke and a
spurious executive action is not acceptable, multiple detectors shall be installed in a voting

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configuration such that:
 Activation of a single detector shall raise only an alarm.
 Coincident activation of any two out of three detectors covering the same fire area
shall constitute a genuine fire and shall initiate executive actions.
3) High Sensitivity Smoke Detectors (HSSD)
Air or smoke is led to high sensitive smoke detectors by a suction system. The HSSD shall include
all sampling pipes, pump and sampling chamber equipment. The detectors shall be used for
internal ceiling mounting.
4) Manual Alarm Call Points
Call points shall be used to supplement the automatic fire detectors and be of pull button type, with
key reset and protected from accidental operation by a lift up flap. The call points shall be used for
indoor, outdoor and Ex-Zone applications.
1.26 Interfaces
The following interfaces are provided for F&G system.
 Interface to air condition and ventilation system respectively to different fire areas /
zones
 Interface to local control and monitoring panel to allow monitoring and controls for
separate fire zones
 Hard wired connection between the F&G and Station ESD
 Hard wired connection for external interface for fire protection systems, fire
extinguishing and fixed fire fighting system
 Serial data Interface for Station Control System (SCS)
Signals for all external processing shall be generally provided as NC contacts without any
references to ground or other potential. The contact shall be closed during normal operation and
break open during alarm / fault conditions for all system.
1.27 Fire and Explosion Hazard Management
Fire and Gas Detection and Alarm System design and installation shall have a Fire and Explosion

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Hazard Management Plan (FEHMP) which have to be agreed with the operator of the installation,
fully documented in the operating procedures.
11 EMERGENCY SHUTDOWN (ESD) SYSTEM
1.28 General Requirement
In situations that abnormal process conditions, gas leakage, fire or station facility failure would
lead to consequences such as risk to life, the environmental or significant asset loss, ESD System
should provide certain protective actions to reduce the risk to tolerable level by isolating the risk
source (hydrocarbon inventory) and depressurizing the concerned vessels and pipeline sections.
ESD system shall be based on highly robust and reliable modular electronic PLC, and allows
automatic and manual activation of emergency shutdown from agreed locations. In pursuance of
this, the number of trips, and the complexity of the ESD controls and logic should be minimized as
far as possible. Different levels of shutdown shall be provided:
 Station ESD level
 Unit ESD level
 Process ESD level
In case of a leak in the process piping or a fire at the compressor station the inlet and outlet ESD
valves of the compressor station will be closed automatically and isolate the station from its
upstream and downstream process facilities. All process equipment like separators, compressors
and air-coolers and all above ground pipe sections at the station will be depressurized to a vent
located at remote site. The actuating devices shall be fail safe structure.
Shutdown functions SHALL be limited to those required for safety, based on the upset condition
detected. The main production process SHALL not be unnecessarily interrupted. The actual
course of action to be taken by the ESD System in response to each input signal SHALL be in
accordance with Cause and Effect Charts.
Shut down can be activated manually when specified on the PID's and according to the Cause &
Effect by Local Shut down Button located near the equipment or on the package panel in the field.
The ESD Operator Interface SHALL be situated in the control center room. It SHALL provide
manual shutdown and manual depressurising of the FACILITIES, as well as detailed annunciation
of system status. Manual overrides and resets of the ESD System SHALL be displayed in the

Document Title:
PHILOSOPHY
operator interface.
Redundant field initiating devices SHALL be provided based on the result of the SIL Study. If only
two instruments are used for redundancy, a discrepancy alarm SHALL be implemented to detect
that there is a discrepancy.
If redundant Controlling devices are required, such as two ESD valves, the controlling output
signals to the valves SHALL be diversely routed and originate from separate cards.
Initiating devices and actuators SHALL be hardwired directly to the ESD System, which SHALL
contain the required monitoring, and control equipment, and shutdown logic. The PCS Operator
Interface SHALL provide audible and visual annunciation of the status of the ESD System, and
manual controls to enable Operator intervention for control, maintenance and testing.
Under normal operating conditions, contacts from initiating devices SHALL be closed, and open for
alarm. Actuating devices SHALL be normally energized, and deenergized to trip.
For analog inputs, line monitoring will be introduced in the software as Signal Fail Low with
individual alarm for less than 2mA and Signal Fail High with individual alarm for more than 22mA
for an ESD system. The failed instrument will be alarmed in PCS workstation.
1.29 ESD & MOS Operator Console
An ESD console SHALL be provided in Control room with Manual Pull Buttons for emergency
shutdown and SHALL be hardwired to the ESD system. ESD console SHALL have provisions to
execute shutdown at different ESD levels i.e. Plant Level, Unit Level, sub-system or process level.
Plant FACILITIES wide RESET Push Button SHALL also be installed on it to reset shutdown or
abnormal state of a level. This Reset PB also helps to check whether the different ESD Levels are
in normal state or not. This Console shall also be provided with Key Operated MOS switches with
normal and bypass for selective instruments and Plant shutdown actuating devices.
1.30 Redundancy
Where the logic system is based on PLC technology, then as a minimum, redundancy SHALL be
provided. Redundancy within the ESD System SHALL , in minimum, apply to processors, power
supplies and communication with PCS.
Any failures within the ESD System, which leave the ESD System unable to respond to a valid
shutdown, SHALL be alarmed with details in the ESD system diagnostics and with common alarm

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PHILOSOPHY
at the PCS maintenance work station.
1.31 Interface to other systems
The ESD System SHALL interface with other systems to receive shutdown initiation requests or to
instruct equipment to shutdown. Typically these other systems will include turbine compressor
control system, package unit control panel, motor control centre.
All interfaces of this nature SHALL be via discrete volt-free contacts.
The interface between ESD System, PCS and F&G System shall be redundant communication
link. This link SHALL be for diagnostics, first-out alarm, shut down alarms, reporting from the ESD
to the PCS and for selected commands from the PCS to the ESD.
Faults or malfunctions within systems, which the ESD System is interfacing to, SHALL not have an
impact on the operation of the ESD System.
1.32 Fault Monitoring & Testing
The ESD System SHALL include self-test and fault detection systems.
Monitoring hardware SHALL be kept to a minimum and as simple as possible. Any failure in the
monitoring circuit SHALL be alarmed to Operator Station. It SHALL be possible to monitor and test
the components comprising the ESD panel while the system is in normal operation.
1.33 Sequence of Events
ESD system SHALL have provision to independently time stamp SOE events down to 100 msec
resolution and the SOE recorded events SHALL be available at the Engineer or Operator stations.
1.34 First out Alarm
ESD system SHALL be designed with a provision of First out Alarm philosophy. ESD logic SHALL
have capability to detect first shutdown event and relay the event message to Operator Station.
First Out capability SHALL be provided for each ESD Level and Process Unit/equipment.
1.35 Start-up override
Start-up overrides, where required for inputs that are in the trip state until the process has started,
SHALL be initiated from PCS. The command transferred via a Communication link SHALL initiate
an appropriate timed override within the ESD system, which will feedback a start permissive to the
PCS. The logic SHALL automatically trip the process if the process fails to achieve healthy status

Document Title:
PHILOSOPHY
within timed period.
1.36 Initiating Devices
Input signals to the ESD System SHALL be normally switches used in the field, they should be
snap acting type arranged such that shutdown initiation is caused by opening contacts.
Voting philosophy (1OO2D) shall be finalized in general after HAZOP study and SIL determination
by the CONTRACTOR.
Where initiating inputs to the ESD System are from other systems, these should be arranged NC
contacts as described above.
ESD Level or Unit Pull buttons will be installed in the control room on the operator console, as
described in “ESD & MOS Operator Console” section.
1.37 Final Actuators
Outputs from the ESD control circuits SHALL operate shutdown valves installed in the process
piping (via a suitable solenoid valve), or trip other equipment (either directly or via relevant control
panels).
Shutdown valve actuators SHALL be air operated, and SHALL be preferably spring return to the
safe position. Double acting air operated actuators are not recommended and SHALL limited to
where valve size and/or operating time constraints require this approach.
Each air operated actuator shall be provided with a filter and a block valve. In addition, for each
double acting actuator of ESD valves, an air reservoir to ensure security of air supply in the event
of leakage, or Instrument Air failure shall also be provided. Each air reservoir SHALL have
sufficient capacity (volume and pressure) to enable three strokes (one stroke is one full open or
close operation) of the valve it is serving.
Air to each shutdown valve actuator SHALL be controlled by a normally energized solenoid valve
powered from the ESD control circuit. On loss of power to the solenoid, the air SHALL be
exhausted thus causing the shutdown valve to move to, or stay in its predetermined safe position.
All on-off shutdown valves SHALL be fitted with status switches monitoring both open and closed
positions for status indication at the PCS Operator facility. Local indication on on-off valve body
SHALL also be provided.
Valve operation SHALL only be possible if ESD System logic has been reset at the Control Room,

Document Title:
PHILOSOPHY
and the initiating condition is either healthy or inhibited by Start Up Override in operation.
Control valves SHALL not be used for ESD Service.
1.38 Depressurizing Valves
When automatic or manual de-pressurizing facilities for equipment containing hydrocarbons are
provided, the depressurizing system SHALL be designed as per API RP 521 to reduce the
pressure contained within the equipment to one half of the equipment design pressure within 15
minutes or as recommended by equipment or package SUB-CONTRACTOR / mechanical design
of the system. Depressurizing logic SHALL be implemented in Plant ESD system.
1.39 Cables
Detailed Specification for cables in ESD use is defined in the attached document “Specification for
Instrument Cable” (QDR-GCS-ESJ-SPC-1006).
1.40 Operation of ESD Valves
ESD valves have two operating positions, a fail-safe position that the valve takes in case of an
emergency and a normal operating position.
11.1.1 Valve to fail safe position
The valve will go to the fail-safe position when the ESD system deenergizes the corresponding
solenoid valve. This command is issued according to the Cause and effect Charts in the following
cases:
 Automatic initiation when the ESD detects an abnormal condition from a field sensor
signal, or other system,
 Manually from the PCS when the control room operator initiates a subsystem ESD
command,
 Manually from a local valve actuator or a local panel push button.
11.1.2 Valve return to normal position
An ESD valve can only return to normal (open/close) position when the operator locally pushes the
open/close button on the valve. The push button design will prevent the operator from doing
disoperation. This switch will only be active if the control room operator has reset the shut down

Document Title:
PHILOSOPHY
sequence and if all permission to open are in a healthy status.
1.41 Valve return in control
After an ESD when the operator resets the sequence, the PCS configuration shall keep the valve
in safe position, leave the controller in manual. The valve shall return in control in auto mode under
normal operation by switching over by the operator from the PCS console.
1.42 Limit switch on valves
Limit switches on valves SHALL be proximity switches following fail-safe design. When the valve is
open, OPEN Limit switch SHALL be closed, and CLOSE Limit switch SHALL be open and vice
versa.
12 ALARM SYSTEM
1.43 Configuration
Alarm annunciations shall be sent in different light colours and different audio tones; alarm
annunciators shall be arranged in such a way that they can alert every personnel at every possible
position.
Alarm & Bypass System SHALL be part of Operator Software Package and SHALL be
configurable by Engineer as well as Operator Access Level.
As a minimum, alarm system equipment installed outdoors SHALL be suitable for the area
classification and environment conditions.
1.44 ALARM MANAGEMENT
12.1.1 General
1) Alarm System and its audible-visual alarms SHALL be provided to call the operator's
attention to abnormal process conditions.
2) Emergency shutdown, drilling, CO2 release and process alarm conditions SHALL each
provide a distinctive and different audible-visual alarm.
3) Messages SHALL be legible to operators sitting at normal operating stations to a person

of normal eyesight. Messages SHALL be in English.
4) Messages from a specific unit or area SHALL pop up in the same place on the same

Document Title:
PHILOSOPHY
display each time.
5) Any hardware or software for making changes to messages in the field SHALL be
provided along with all manuals.
6) An alarm history page or pages SHALL be provided showing active, acknowledged.
7) In General, whole system reporting SHALL be divided into two states or categories,
ALARM and EVENT. These will be further categorized, stored and displayed as explained
further in this document.
12.1.2 Alarm Banner
1) Alarm Banner SHALL be provided on Operator Work Station which SHALL always stay or
will act as pop up screen.
2) Alarm banner SHALL indicate existing or current alarm through Color animation.
3) Alarm Banner SHALL point to different Plant graphics or Unit areas. Each Compressor &
utility area graphics SHALL be individually accessible through Alarm Banner, which
SHALL guide operator to navigate rapidly to any process or system alarm.
4) Alarm Banner SHALL also indicate type of alarm and if possible SHALL represent alarm
priority.
5) Running or Shutdown status of major equipments i.e. Compressors SHALL be directly

displayed on the alarm or a separate banner. Shutdown event of major equipment SHALL
be identified through unique audible tone and visual colour from the Operator Station.
12.1.3 Alarm & Event Loggers
1) Separate Loggers for Alarm and Events SHALL be provided.
2) Alarm and Event Loggers SHALL always be accessible at any time or position by the
operator though single mouse click on the Operator Station.
3) Alarm display Logger SHALL be divided minimum into two, Current Alarm and Alarm
History.
4) Current Alarm Logger SHALL has the option of showing Alarms with or without
Unacknowledged Alarms.

Document Title:
PHILOSOPHY
5) Alarm and Event Logger SHALL have the option of Sorting and Filtering based on
different categories i.e. priority, alarm type, Alarm groups.
6) Alarm & Event Logger SHALL have the option to disable individual Alarm or Event
logging. This functionality SHALL be accessible through proper User login & passwords.
Disable action SHALL leave the actual Logic in PCS controller non-functional or it is sort
of virtual Bypassing. Difference between Disabling function and actual Bypass is that
Operator Bypass action does not disable the alarm but only keep the logic normal
irrespective of the device status. However, disabling function SHALL always leave the
Logic disabled to function and SHALL not send alarm to the operator. In case of Bypass
functionality, Alarm generation feature is still working and reporting to Operator Station.
7) Alarm and Event Logger SHALL have the option to acknowledge individual alarm or
event. This SHALL require minimum actions on part of Operator i.e. maximum of two
mouse clicks.
12.1.4 Alarm Priority
All the alarms SHALL have configurable priority and assigned during detailed design and
engineering. However, in philosophy they SHALL be categorized based on following:
1) Controller Status & Diagnostic Alarms
 Communication Status
 Controller & I/O Hardware Failure
 Alarm Defeated (Maintenance)
2) Instrument Failure Alarms
 Instrument Out Of Range
 Open/Shorted Thermocouple
 Link Fails (Remote I/O to PLC, etc.)
3) Process values
 Shutdown Alarms: High-High/ Low-Low
 Process Alarms: High/ Low


Document Title:
PHILOSOPHY
Priority of Alarms SHALL define the sequence of Display in both Current and History graphics on
the Operator Station.
12.1.5 Alarm Types
Operator Station SHALL have configurable option of defining variety of alarms. Following Alarm
types SHALL definitely be available in the in the package.
1) Absolute Threshold
 High
 High-High
 Low
 Low-Low
2) Rate of Change
3) Snooze Alarm
Snooze Alarm re-alarm if the condition persists beyond selected time after acknowledging it.
4) Alarm Dead bands
12.1.6 Alarm Grouping & Hierarchies
All Alarms SHALL be assigned Alarm Groups and sub-Groups. Groups SHALL be defined as per
following philosophy, but complete strategy SHALL be defined by the SUBCONTRACTOR. Alarm
Groups SHALL be based on process Areas, Unit Compressors and Utilities. Each Compressor
SHALL be assigned a main Alarm group and divided into sub-groups of compressor alarm
categories. Alarm Loggers SHALL have option to sort or filter the Alarms based on Alarm groups.
12.1.7 Alarm Cycle & Animation
Alarm Cycle represents combination of Alarm State and operator actions that it SHALL pass
through at a time. Each Alarm stage is represented by an Animation of color or Blinking on the
Alarm Logger. System supplier SHALL define details of Alarm Cycle during Functional Design
stage and submit it for approval. However, following details should be considered during designing
as a sample:

Document Title:
PHILOSOPHY
Alarm State Acknowledged Colour Blink
High No Low Intense Red Yes
High Yes Low Intense Red No
High-High No Red Yes
High-hig Yes Red No
Alarm Cycle Example: Normal Alarm State  Alarm (Unack)  Alarm (Acked)
Alarm SHALL not exit from the Current Alarm logger unless and until it is Acknowledged by the
Operator and has returned to Normal.
12.1.8 Operator Action Journal
Operator Station package SHALL have Event logger to log all the Operator actions with the current
user login information to keep tracks the actions.
12.1.9 Alarm & Event Printing
System SUB-CONTRACTOR SHALL provide Alarms and Events on papers by line printer and / or
page printer on demand, periodically and event initiated. Commissioning Spares of Cartridges and
printer accessories SHALL also be provided.
1.45 BYPASS MANAGEMENT
12.1.10Bypass General Requirements
1) All the Alarms SHALL have Bypass facility with proper user access. When put into
Bypass, respective process or ESD logic SHALL consider the input device as Normal.
2) Bypass action by the operator SHALL be communicated to PCS or ESD system through
serial communication to disable the Process and Shutdown Logic of respective Input
device. However, Bypass SHALL not disable the alarm functionality itself.
3) Each Transmitter or Field switch (Input device) when put into Bypass SHALL be indicated
with Yellow color of animation on the operator graphics.
4) Each Transmitter or Field switch (Input device) SHALL be placed or removed in the
Bypass only in their respective Graphics.

Document Title:
PHILOSOPHY
5) Bypass for whole station SHALL also be displayed on one common screen called
“Bypass Screen”. These Bypass indications SHALL take the operator to respective
graphic when clicked by the operator.
6) When a device is put in Bypass, system SHALL alarm the operator with a reminder about
the Bypass after a configurable preset time. This option can be disabled by the
Engineer/Operator.
7) One Bypass Command from the Operator Station SHALL be enough to completely
bypass a Transmitter.
8) Any communication breakdown between the Operator Station and PCS /ESD system
SHALL not remove the Bypass from the Logic. Each command from the Operator Station
SHALL has a feedback from the PCS /ESD to confirm that the Input device has been put
into Bypass.
12.1.11Maintenance Override Switches
A MOS console, to be installed on operator Console, SHALL be supplied by the Control System
SUB-CONTRACTOR. Number of MOS SHALL be finalized during detailed engineering, however,
to avoid conflict and for the sake of clarification minimum No. of MOS SHALL be 10, and P&IDs
SHALL be guiding document for this purpose.
MOS SHALL cater number of important Shutdown devices for the new facilities for maintenance
purposes at the Operator Console, easily accessible during normal operation. Each MOS SHALL
be of Key-Locked type and properly tagged with engraved labeling system at the bottom of each
key switch.
1.46 DOCUMENTATION
The System Configuration & technical details SHALL be the responsibility of the vendor. This
document SHALL elaborate further on the technical requirements contained herein. The vendor
SHALL produce a System Functional Specification to clarify and enhance the details of this
specification. Following documents SHALL be prepared and forwarded for approval.
1) Alarm Philosophy Block Diagram
2) Alarm Groups List
3) Available Alarm Types, Features & Characteristics details


Document Title:
PHILOSOPHY
4) Alarm Configuration & implementation details with selected features & characteristics
5) Alarm & Event Logging configuration details (Features & Characteristics)
6) HMI Guidelines & philosophy (These guidelines SHALL cover color coding, typical
symbols to be used in the graphics, screen navigation guidelines, utility screens etc. The
guidelines here should allow the detailed implementation of the graphics to take place
without further clarifications and SHALL define the expectations at the completion of the
PROJECT.)
7) Bypass Implementation Philosophy (Configuration philosophy and HMI interface details).

QDR-GCS-ESJ-REP-1000 RevA

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OWNER PMC OIL & GAS DEVELOPMENT COMPANY LTD CONTRACTOR

QADIRPUR COMPRESSION PROJECT

INSTRUMENTATION AND CONTROL

A Issued For Review 8-Feb-2007 LY QBP LSH

Rev Description Date Prepared Checked Approved Client

QADIRPUR COMPRESSION PROJECT

1.1 Process Description.............................................................................................................................. ......5

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1.27 Fire and Explosion Hazard Management............................................................................................. ...19

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1.1 Process Description

 Phase A – Operation at constant flow rate

 Phase B – Operation at constant inlet pressure

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- Temperature Max 50 °C (122 °F)

4 ABBREVIATIONS AND DEFINITIONS

COMPANY Oil & Gas Development COMPANY Limited (OGDCL)

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SCS – Station Control System

API American Petroleum Industry Standards

CE Declaration of Conformity to European Standards

ISA Instrument Society of America

DIN Deutsche Industrie Normen (German Industrial Standard)

IEC International Electro-technical Commission

6 UNITS OF MEASUREMENT AND SCALES

Vapour flow ft3/h, MMscfd Mass Flow lb/h

Pipe diameter in Volume Flow bpd/gpm

Heat Duty MMBtu/h Molar Flow kmol/s

Specific Heat kJ/kg Density lb/ft3

Heat Transfer Btu/hft°F Viscosity cP, cS

Length km, m, mm Current A

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Mass lb Power kW, MW

Time s, h, d, a Rotation rpm

Pressure psig, psia Noise dB(A)

QDR-GCS-ESJ-SPC-1001 Specification for Station Control System

1.2 General Information and Description

 reliability and safety

 single point or single loop effected failure

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 support of advanced diagnostic and quality assurance goals

1.3 System Architecture Overview

The system uses three main layers in control structure:

1) Supervisory Control and Operator Interface Layer

2x Operator workstations

1x Engineering workstation

1x Sinoptic Screen

1x Operator console for Engine Unit Control

2) Autonomous control, Data Processing and Process Interlock Layer

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Station Control System (PLC based)

F&G Alarm System

UCS #1 through UCS #6

1x Communication Interface

2x Data Servers

3) Data Acquisition Layer

System I/O channels

Unit control I/O channels

Remote I/O channels

1.4 Software Architecture

The operating system is windows.

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1.5 Networking and Communication