1        Introduction

1.1        Introduction of GE  

1.1.1        General introduction

GE is a global business founded by Thomas Edison over 100 years ago. With great contribution of GE former chairman & CEO: Jack Welch, a great business leader, now GE is the most profitable and admired company in the world. GE’s new chairman & CEO: Jeff Immelt has been officially on board to operate GE each business since September 7, 2001.
GE is the only company in the DOW Jones Industrial Index included in the original 1896 edition. Up to now,
 GE stock has the biggest market value and also GE is one of 8 companies that have the financial rating up to AAA.
GE is a diversified international company that integrates technology, manufacturing and service as a whole. GE’s goal is to make each of our businesses as No. 1 player in each business segment by utilizing the win-win strategy. So far, GE has been running business in more than 100 countries and GE has close to 315,000 employees worldwide.

1.1.2        GE Rankings

GE has been awarded as:
·         2004 Catalyst Award - Catalyst (2004)
     
·          
·         100 Best Companies for Working Mothers - Working Mother (2003)
     
·         World's Most Respected Company - Financial Times (1999, 2000, 2001, 2002, 2003, 2004)

·The Scientific American 50 Award - Scientific American (2002)
 
 
·         Global Most Admired Company - Fortune (1999, 2000, 2001, 2002)
 
 
·         America's Most Admired Company - Fortune (1999, 2000, 2001, 2002)
 
 
·         10 Best Board of Directors - Business Week (2002)
 
 
·         First place: The Super 500 - Forbes (2003)
 
·Fifth - Fortune 500. If ranked separately, all 11 GE businesses would appear on the Fortune 500.
 
 

1.1.3        GE strong performance

Financial Highlights
·         2003 Revenues: $134.2 billion
·         2003 Earnings: $15.6 billion ($1.55 per share) before cumulative effect of accounting changes; $15.0 billion ($1.49 per share) after changes.
·         2003 Cash Flow from Operating Activities: $12.9 billion
·         Dividends: $0.20 per share quarterly. Dividends, paid every quarter since 1899, have increased every year since 1975.
·         Shares Outstanding: 10.019 billion
·         Number of Share Owners: 4 million
·         Stock Splits: GE shareowners have approved nine stock splits, most recently a 3-for-1 stock split in April 2000. Shareowners have also approved four 2-for-1 stock splits since 1983. One GE share purchased before 1926 is now worth 4,608 shares.
·         2003 International Revenues: $60.8 billion (45% of total revenues)
·         2003 R&D Expenditures: $2.7 billion
·         2003 Total Assets: $647.5 billion
The following are comments from Chairman & CEO of GE, Jeff Immelt, in the GE’s annual report of 2003:
Through the cycles, GE’s long-term financial goals are: revenue growth of twice the U.S. Gross Domestic Product (GDP); 10%-plus annual earnings growth; operating cash flow growth greater than earnings; and a return on total capital exceeding 20%.
…Here is how GE performed in 2003:
·         Revenues grew 1% to $134.2 billion. Excluding Power Systems and the expected impact of the decline in U.S. gas turbine shipments, revenue grew 6%, about twice GDP growth.
·         Earnings before required accounting changes grew 3% to $15.6 billion, or $1.55 per share. Excluding Power Systems, earnings grew 17%.
·         Cash flow from operating activities was $12.9 billion, up 28%, reflecting a $2.2 billion improvement from inventory, receivables and payables. Return on average total capital remained strong at 19.9%.
·         The Board of Directors increased the dividend 5% for GE’s 28th consecutive annual increase. At year-end, GE’s yield was 2.5%, a 40% premium to the S&P 500. GE returned $8 billion to investors in 2003, primarily through dividends.
·         GE remained one of only seven triple-A rated industrial companies. The Company continued to reduce “parent-supported debt” at GE Capital, with total reductions of more than $9 billion over 2002–03. Commercial paper as a percentage of total debt remained below 30%. 
·         Total return for GE shareholders (stock price appreciation assuming reinvested dividends) was 31% versus the S&P 500’s total return of 29%. At year-end, GE traded at a price/earnings ratio (P/E) of 20, a slight discount to the S&P 500.
·         GE continued to earn the respect of the business world. For the sixth consecutive year, GE was named “The World’s Most Respected Company” in the Financial Times annual global survey of CEOs. GE was ranked first for governance and integrity.

1.1.4        GE business composition

GE is divided into the following 11 world-class businesses:
·         GE Advanced Materials
·         Commercial Finance
·         Consumer Finance
·         Consumer & Industrial
·         Energy
·         Equipment Services
·         Healthcare
·         Infrastructure
·         Insurance
·         NBC
·         Transportation

1.2        GE Intelligent Platforms Introduction (GE IP)

 
World and Americas’ Headquarters, Charlottesville
GE Intelligent Platforms is a global enterprise dedicated to helping companies around the world better manages their systems and processes through factory automation solutions. Our reputation rests on our unparalleled experience in automation control, our practice of first-class research and development, our expertise in engineering and systems integration, and our award-winning manufacturing facilities. With world headquarters in Charlottesville, Virginia, GE IP has operations serving the Americas, Europe, and Asia with a total of 1,500 employees.
Our Mission:
At GE IP, we work toward a single goal: To improve our customers' productivity with the best automation technology, reliability, and services worldwide.
Dedication to Quality
GE IP was one of the first companies in the United States to become a certified ISO 9001 manufacturer, after meeting the most comprehensive and stringent of all ISO standards set by the International Organization for Standardization. To assure international acceptance of this certification, we are registered with the British Standards Institute (UK). To serve our European customers, we are also aggressively meeting CE mark standards as they are determined.
We re-dedicate ourselves to superior products and services every day through our Six Sigma Quality Initiative. Six Sigma provides statistical tools for measuring customer needs and satisfaction, and showing ways we can improve even further. For our customers, Six Sigma means getting what they want, when they want it, on time, undamaged, and working – and that their experience with GE IP is the best it can be.
GE Intelligent Platforms offers customers the following products:
·         PLC controllers: Micro & Nano, Series 90-30, Series 90-70, PAC3i, PAC7i, Versamax PLC
·         High Availability and reliability Safety Control System: GMR, TMR, HBR
·         I/O: Genius I/O, Field Control I/O, Versamax I/O
·         Operator Interface: Datapanel, Quickpanel, Quick panel view&Control, Display Station etc
·         Motion Control
·         Software Solutions: Intellution iFix HMI/iHistorian/iBatch/iWorkinstruction/Plant intelligence, Cimplicity Plant Edition, Cimplicity Advantage (Manufacture Execution System--MES), Cimplicity EAM (Enterprise Asset Managemant), Digital Cockpit (Enterprise Information Portal – EIP) etc.
·         Services: Product Service, Professional Service, Training Service etc.

2        General

2.1        Codes, Standards, Regulations and References

The proposal is based on the following Specification and standard:

NO	Standard Name	Standard Number
1	Petroleum chemical instrument grounding design specifications
2	Petroleum chemical instrument power supply design specifications
3	Industrial production process of the application of the safety instrument system
4	Oil and gas pipeline and instrument control system design specifications
5	Oil and gas pipeline and computer control system design specifications
6	Reliability, maintainability terms
7	Distributed control systems engineering design rules
8	Process measurement and control instrument function mark and graphic symbol
9	Oil and gas engineering code for fire protection design
10	Automation instrumentation engineering construction and acceptance specification
11	Building electronic information system lightning protection technical specifications
12	Uninterrupted power supply equipment
13	Electronic computer site general specification
14	Industrial automation instrument, ark, Taiwan, box
15	Explosion and fire danger environment power device design specifications
16	Electronic computer room design specifications
17	Oil liquid and gas metering standard reference conditions
18	Industrial process measurement and control instrumentation and display instrument accuracy level
19	The international system of units and its application
20	Computer room floor with activities of technical conditions
21	Hardware Testing of Digital Process Computer
22	Degrees of Protection Provided by Enclosures (IP Code)
23	Electromagnetic Compatibility(EMC)
24	Electrical Apparatus for Explosive Gas Atmospheres
25	Manual on installation of refinery instruments and control systems
26	Instrument Loop Diagrams
27	Graphic Symbols for DCS/Shared display Instrumentation Logic and Computer system
28	Graphic symbols for process display
29	Instrumentation Symbols and Identification
30	Marking of insulated conductors
31	Identification of equipment terminals and of terminations of certain designated conductors, including general rules of an alphanumeric system
32	Functional safety of electrical/electronic/ programmable electronic safety-related systems
33	Functional Safety: Safety Instrumented System for the Process Industry Sector
34	Programmable Logic Controller

 

3        Scope of Work & Supply, Spares and Delivery Requirements

The project includes the design, manufactures, inspection, testing, preparation for shipment and training of the central control system for the FPSO, Wellhead Platform and Living Quarter of Enping Oilfield Development Project.
 
The central control system is as a ‘turnkey’ project. GEIP is responsible for system design, integration, programming, configuration, system test, packing transportation, running until after-sales service and training based on the specification, other relevant design documents and standard. In addition, GEIP is responsible as well for quality, time schedule and service.
 
·           The central control system (CCS) shall include Process Control System (PCS), Emergency Shutdown System (SIS).
ü  The PCS performs the monitoring and control functions for the facilities. This includes control (pump starting and stopping control, valve split range control and the other process related functions), data acquisition, data presentation (operator display), sequencing, alarming, data logging, trending and reporting features.
ü  The SIS shall perform personnel and equipment safety monitoring and protection and all associated shutdown functions.

3.1        Material

The detail materials refer to the Bill of Material

3.2        Service

Service includes design, engineering, manufacture, perform system configuration, test, supply and deliver the complete system, including the communication interface.
·           Documents and drawings
·           System integration
·           Factory acceptance tests (FAT), include the testing for integration with third party systems and analyzers
·           Packing, shipping
·           Cable wiring (except the cable for association between cabinets) are not included in our scope.
·           Cabinets in place and assemble are not included in our scope.
·           Start-up assistance
·           Site acceptance test (SAT)
·           Training
·           Guarantees and Warrantees

4        Technical Introduction

4.1        PAC8000 (PCS) System Description

4.1.1  Description for Proficy Process System

·          GEIP Procify Process System PAC8000 is a new generation of process automation control system for process control, discrete control, policy control, process monitoring, and emergency parking offers a complete integrated solution. PAC8000 system is truly open system, using the advanced secure bus architecture; double combination of the hardware system, a fully redundant fault-tolerant technology and unique fail-safe strategy, making up 99.999% system reliability. High-speed large-capacity memory controller and to ensure implementation of the system speed and accuracy.
·          Carriers
·          The controller carriers and the I / O module carriers using the advanced Railbus technology, each controller carrier can be installed a pair of redundant controllers, a power monitoring node, two 9-pin RS485 interface, support for MODBUS RTU protocol. I/O modules carriers are available to support four or eight I/O modules. Module and modules isolated from each other, support hot swap.
·          Main Controller
·          All controller, dual Ethernet and serial communication interfaces, supported API, Fieldbus, Modbus, HART, peer-to-peer communications, as well as OPC, redundancy can be achieved, can be directly installed in the risk of zone 2, supporting Hot swap.
·          I/O Modules
·          I/O modules can be optionally installed control room or field area, channel isolation, monitoring, and LED indication, support a variety of signal types, support hot swap. Analog Input A / D converter resolution of 16-bit, analog output D/A converter resolution of 12, able to line circuit detection, built-in input variables linearization, engineering units conversion, square root filtering, alarm and the cold junction temperature compensation capabilities.
·          Field terminals
·          Removable, small size, Field terminals provide the interface between the I/O modules and the field wiring. They include fusing and loop-disconnect as options. A mechanical keying system prevents an I/O module from being connected to the wrong type of field terminal. The field signal can be directly connect to field terminals of IO module, saving field terminal row of investment.
·          Power Supply
·          With N +1 redundancy, the floating design of the power supply module. Under normal circumstances, the two power supplies each be responsible for 50% of the electricity load, while one a power supply failure, the other a power to bear 100% of the load.
·          In these applications, PAC8000 to a large extent a common platform reduces the testing and maintenance costs, combined with a few testing tools to control the logic assessments, including the integrity of the parser and cross-reference analyzer.
·          Programming package
·          PAC8000 programming package, is a complete project development environment for configurable instrumentation, including an index, the control strategy (process and discrete), static analysis, integrity analysis, cross reference analysis, process visualization (control panel), history (record of alarms and trends), online downloading and project management and many other features of the project works.
·          Communication
·          Two Ethernet ports, four serial communication port integrated into the CPU Carrier, fully support the Modbus TCP protocol, Modbus RTU industrial serial communication protocol, RS232/422/485 serial communication protocol, HART protocol, as well as FF, Profibus and fieldbus protocol. Operator station and the controllers can be redundant communications to ensure security and reliability of the operating system, full adoption of OPC technology; plant-level information management system provides a convenient data interface.

4.1.2  System Features

·          Open control platform
·         System uses industry-standard open protocols, Communication system network for the international popularity of redundant fault-tolerant Ethernet architecture.
·          
·          Modularization
·          Control System's modular design makes it easy for users to build a complete complex system. Expansion of flexible can be achieved from small to several loops of different sizes as large as thousands of circuit applications.
·          Environmental stability
·          Operation in Class I, Division 2 and Zone 2 hazardous areas with field wiring extending into Division 1 and Zone 1/0 areas
·          ISA Level G3 corrosion
·          –40°C to +70°C operating range
·          5% ~ 95% relative humidity
·          30G shocks and 5G vibration
·          High Reliability
·          PAC8000 wide redundancy can provide you with a variety of redundancy options, such redundancy may include:
·          Redundant controllers
·          Redundant Control Network
·          Redundant system power supply
·          Redundant controllers are used for important control applications. Use of redundant interlock means from a master controller to the standby controller, disturbance-free switching. PAC8000 controller, redundant model of support online and on-line configuration of hardware replacement, redundant controllers in real-time information sharing between the updated redundant systems makes the application easier. PAC8000 also supports LAN redundancy. Each controller has two independent Ethernet interfaces; each interface can be connected to a separate network to realize a fully redundant LAN. Redundant power supply is used in important applications, when a power failure is still able to ensure continuous operation of the system.
·          Peer to peer communications
·          PAC8000 Controllers can share data with each other via peer-to-peer communication over Ethernet. The ability to make important information can be effective in the field shared between controllers without going through the control room.
·          On-line changes
·          PAC8000 allow on-line configuration changes during testing, start-up, and maintenance phases. This significantly accelerates system start-up and reduces operation downtime. It is easy to configure the control project in a single step and automatically generate the point data-base, HMI, PID control panel and graphic symbols will be automatically updated.
·          Comprehensive Self-Documentation
·          PAC8000 Controllers automatically generate as-built system documentation including I/O configuration reports, cross reference analysis, bill of materials, instrument index, system start-up, maintenance information and wiring diagrams. The system drawings are kept current, providing you significant timesaving. 
SOE function
PAC8000 provides powerful SOE function, which has high-resolution (millisecond) analog record function in addition to common digital SOE function. When a key event (e.g. shut-down) occurs, the change of related variables, including switch signal and analog signal, are recorded, which facilitates fault diagnosis and handling. PAC8000 provides 32-channel SOE card, which has all functions of switch input card and high-speed SOE function with resolution 1/8ms and accuracy 1/4ms. PAC8000 system achieves clock synchronization function through NTP (Network Time Protocol), with accuracy up to ±3ms. The complete SOE software integrated into the PAC8000 system c configuration software allows the management, storage, query, print and treatment of SOE. All events of controller are saved automatically in SOE station, and the save time, event number, and “clear events when insufficient storage is available” can be set as required.
Intelligent Devices- HART pass-through
PAC8000 can select to use analogue IO module which support HART pass-through. These HART information can be delivered to asset management system using FDT/DTM technology via control network.
 HART Devices Management System
·   PAC8000 HART devices management software package is a open software which uses FDT/DTM technology to connect to different HART devices. Using HART devices management software, end user can realize read and configure field instruments and devices data or parameters directly from PAC8000 IO module via existing control network.

4.1.3  Hardware Detail Information

4.1.4  System Visualization

The system shall provide industry leading HMI technology for the visualization and interaction required at the Operator Consoles.  The system shall provide full featured HMI visualization capabilities.  

4.1.5  Application Development

1. 
2. 
3. 
3.1. 
3.1.1. 
3.1.2. 
3.1.3. 
3.1.4. 
3.1.5. 

Overview

Visualization application development will be done on the Engineering Workstation.  System shall be furnished with application development tools for configuring projects. A utility should provide for interactive fill-in-the-blank transactions for configuring individual items. An interactive Graphics Editor package is provided to develop screen layouts and to animate a given application. 
The editing package shall include a Wizard / Symbol / Object Library to permit the inclusion of pre-developed or third party graphic objects.  The editing package shall allow Objects/Wizards to be created with the native graphics and scripting language and added to the Library. 

Graphic Creation

The system shall provide an interactive object-oriented editor or workspace that allows creation of graphic displays using a pointing device (for example, a mouse).
A facility shall be provided that quickly toggles, via a mouse click or hot-key, between the graphic building and graphic runtime modes to speed display animation verification during the development process.

Browser

Once an object is created, it shall be possible for the placed on a tree similar to Microsoft’s Explorer program for future re-use.

Properties Window

A properties window, exposing all properties for an object must be available. The properties window must support edit functions for any object selected. 

Active X Support

The graphic screens must be an active X document and have the ability to have third party ActiveX OCX, controls dropped in.

Graphics Pre-Loading

The system shall support the pre-loading (“caching”) of pictures to improve graphic performance.  The use shall be able to set a list of pictures to be pre-loaded when the system starts, or select a maximum number of pictures to be automatically cached in memory as the system runs.

Color Support

The graphics package shall provide support for an unlimited choice of colors with at least 256 colors supported at any one time. The user shall have the ability to create, save, and restore custom color palettes. Each color must have an associated name so users can selected from the color from the name of the color.

Graphic Objects

At a minimum, the following object drawing tools must be supported:
·         Rectangle/Square
·         Rounded Rectangle/Rounded Square
·         Oval/Circle
·         Straight Line
·         Polylines (two or more connected line segments)
·         Polygons
·         Arcs (curved line segments)
·         Chords (a curved line connecting a line segment)
·         Pie Shapes (wedges of a circle)
·         Text
·         Pipes
·         Connection Points
·         Vertical and Horizontal connection lines

Graphic Animation

Each display must have the ability to dynamically update elements in the picture. Defining the method for dynamic update shall be determined by a point and click operation.

Dynamic Properties for Objects

Dynamic properties that may be assigned to an object or group of objects must include the following:
Color changes:
·         Foreground Color
·         Edge Color
·         Background Color
·         Gradient Fill Color
Fill Percentage:
·         Horizontal (Left/Right)
·         Vertical (Up/Down)
Position/ animation:
·         Horizontal (X)
·         Vertical (Y)
·         Rotate
·         Scale
Script Language:
·         Commands on down (mouse button or key)
·         Commands on up (mouse button or key)
·         Commands on mouse click
·         Commands on mouse double click
·         Commands on mouse move
·         Commands on edit
Fill Style:
·         Horizontal
·         Vertical
·         Downward Diagonal
·         Upper Diagonal
·         Cross Hatch
·         Diagonal Cross Hatch
·         True Gradient Fill
Edge Style:
·         Solid
·         Hollow
·         Dash
·         Dot
·         Dash Dot
·         Dash Dot Dot

Tag Aliasing and Tag Group support

The system must support a means of creating single picture that can use any one of a number of different data sources.  For example, the system will provide a PID faceplate “pop up” picture that when opened can display different data from different PID function blocks in the controller, based on which item PID block the user selected.  The manufacture shall provide a PID block and associated faceplates as well. 
The system shall allow the user to create a picture by inserting tag substitution strings in any link in a picture.  A separate tag group file will then be used to cross-reference the substitution strings with the data source. When the graphic is opened, the user can either specify the tag group file to use, or the operator can be prompted.

Command/Scripting Language

The scripting language used by the system should be Microsoft’s Visual Basic for Applications (VBA) (at least version 6.4 or above) or similar. Scripts can be simple or complex and allow users to automate operator tasks, and create automations solutions. 

Scripting language requirements:

·         Animation of objects in pictures.
·         Automatic generation of pictures or objects.
·         Read from, write to, and create database blocks.
·         Automatically run other applications.
·         Incorporate custom security features.
·         Create custom prompts and messages for operators.
·         Access ODBC or ADO data sources.
·         Incorporate and communicate with third party and custom Active X controls.
·         Write custom wizards for frequently performed tasks and offer as Toolbars
·         Allow use of global scripts and global variables.
·         Scripts become part of the graphic screen.
·         Properties, methods, and event of Graphic objects created within the graphic editor or Third party Active X controls used in the graphic screen must be exposed to the scripting language. 

Global Scripts and Variables

The ability to have scripts and variables available across all graphic screens. These global scripts and variables must get loaded when the system is started.

Multimedia Capability

Support for standard Windows 2000 multimedia capabilities, including audio and video, shall be provided.

Faceplates

When configuring the visualization software it must be possible to associate a faceplate with a process function block configured for the controller through the Global Namespace.  All of the points associated with the function block shall be automatically associated in the visualization software with the faceplate graphic. 

Runtime Visualization

Screens created by the visualization software will be used by the operator to monitor and control the process. Real-time values being read from the field devices shall be capable of being displayed in a variety of user-configurable formats.
Alarm acknowledgements from the Operator Console shall be sent to the controller that generated the alarm.  The controller shall then broadcast the new state of the alarm to allow all Operator Consoles to be updated with the new and current alarm state. 

Data Trending

The trending module shall be capable of supporting one or more embedded trends within the runtime graphics user interface.  The following types of trends shall be supported:
·         Trends with Multiple Y Axes
·         Trends with Multiple X Axes
·         Trends with multiple time periods
·         Reference curves
Trend charts shall support:
·         Any number of pens
·         Displays run time and historical data on same chart
·         Allow the user to insert data (i.e., lab data) into a chart
·         Configurable time span
·         Configurable trend direction (left to right and right to left)
·         Configurable Zoom
·         Scrolling Grid
·         Ability to invert Hi and Low limits
·         Minimum of 5 line styles for pens
The trending option shall support display of an unlimited number of pens on a single trend chart. Each pen shall display either dynamically updating data or provide seamless access to historical values based on user request. In addition, user shall be able to compare data from different time periods.
Trending shall support the creation and re-display of files with reference data from the currently displayed trend. This export capability shall produce "CSV" format files so as to be compatible with standard office automation tools such as spreadsheets and databases.  The trending module shall support reading data from "CSV" files for the display of data collected or generated by other applications within the visualization framework.
Users shall be able to analyze trend data by scrolling through time, changing the range for point displays, zooming into an area of the trend and selecting a new time period to display.
Printing of trend charts is required.

4.1.6  Alarm and Message Handling

The system shall be capable of displaying alarm conditions forwarded from the system controllers.  Alarms can be filtered based upon location, priority and other user-selectable criteria.   All operator consoles shall receive the alarms from the controllers.  When an alarm is acknowledged from an operator console screen the acknowledgement shall be sent to the controller, and the response sent back to all operator consoles.  Therefore, if the alarm is acknowledged on one machine then all machines will see that it was acknowledged. 

4.1.7  Time Stamping

A time stamp must be included with every alarm or message.
For alarms generated in the controllers, this time stamp will be generated by the function blocks and will indicate the time and date that the alarm or message was generated.
For alarms generated outside of the controllers and received in the visualization system, the timestamp of when the alarm is received will be used unless the system generating the alarm passes a timestamp into the system. 

4.1.8  OPC Client and Server Interface

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

4.2        GMR (SIS) System Description

Genius Modular Redundancy (GMR) has been developed by GE Intelligent Platforms. GE Intelligent Platforms have for many years provided high integrity safety system solutions to a wide spectrum of industries including: Oil & Gas Exploration and Production, Hydrocarbon Processing, Semiconductor, Transportation and Power Generation. GE Intelligent Platforms has captured this expertise in the GMR integrated system solution.
Based upon globally-available hardware, a Genius Modular Redundancy (GMR™) system consists of a number of modular subsystems, integrated to form a flexible and powerful whole. The number and type of subsystems is completely scaleable to the requirements of the application. Utilizing field-proven Series 90™-70 PLC, Genius® I/O, and VersaMax™ I/O products, GMR provides variable redundancy from the input devices through one, two or three PLC CPU processors to the output devices. GMR implements advanced diagnostics throughout the systems to detect overt and covert failures, increasing system uptime, and reducing Mean Time to Repair by pinpointing faults as they occur.
In a GMR system, less-critical inputs and outputs may be configured for simplex or duplex operation while maintaining triplicated elements for instrument loops requiring the highest levels of process integrity. The result is a system that provides both base regulatory control and safety system functionality.
A key feature of the GMR system is that non-redundant, less critical process control can be configured in the same system as redundant or triplicated safety-critical sections. While a (limited) number of GE Intelligent Platforms PLC products have been TÜV-approved for use in the redundant areas, all GE Intelligent Platforms PLC components can be used in the same system.
TÜV has certified GMR to Safety Integrity Levels (SIL) according to ANSI/ISA S84.01, IEC 61508, DIN V19250, DIN/VDE 801 and other international standards relating to the design of Programmable Electronic System (PES) Technologies.
The GMR system has received TÜV type approval for use in safety-relevant systems where the safe state is de-energized, such as Emergency Shut Down (ESD) systems, or where the demand state is energized, such as Fire & Gas systems or Boiler Management systems.
The flexibility of the GMR system makes it possible to apply the exact mix of redundancy options required by the application. This section describes the architectures that have been certified by TÜV and their expected Safety Integrity Levels (SIL).
As described previously, the GMR System can be thought of as consisting of three subsystems, the Input Subsystem, the Processor Subsystem, and the Output Subsystem:
In accordance with IEC61508, the highest SIL rating the GMR system can achieve is equal to the lowest SIL rating of these three in-series subsystems. For example, to achieve a SIL 3 control loop, all three GMR subsystems involved in implementing that loop must meet the SIL 3 requirements. The tables that follow list the maximum SIL Rating for different types of GMR input, processor, and output subsystems. (These SIL Ratings correspond directly to DIN Class Ratings; SIL1 = DIN Class 2/3, SIL2 = DIN Class 4, SIL3 = DIN Class 5/6).

GE Intelligent Platforms has received TÜV type approval for the GMR system, just as specification specified in this project, for use in safety relevant systems where the safe state is de–energized (e.g. ESD, SIS systems) or the demand state is energized (e.g. Fire & Gas systems, Boiler Management systems). The type approval certificate at the time of printing is 968/EZ 106.00/00.

4.2.1  Sub-System of GMR

The basic parts of a GMR system are the input subsystem, the processor subsystem, and the output subsystem. These subsystems can be designed to provide the exact mix of redundant and non-redundant discrete and analog equipment needed for a broad range of critical control applications.
Genius Modular Redundancy provides:
·         A high degree of self-test and monitoring with diagnostics
·         Fault tolerance.
·         Fail safe
·         Support for centralized or fully distributed systems.
·         Scalable voting.
The proposed system is designed based on following assumption:
·         Normally-on inputs with normally-energized outputs – Safety System (Shut down Level ¾)
·         Normally-off inputs with normally-de energized outputs – Safety System (Shut down Level ½)

4.2.2  The Processor Sub-System

A GMR system normally consists of one to three identical processors running identical application software. Each processor is normally connected to the same input and output subsystems. Each processor receives all inputs and performs voting for discrete inputs and mid-value selection for analog inputs. Each processor computes the required outputs as a function of the inputs and the application program logic. Each processor then sends its own output data to the Genius blocks.
Integral to the operation of a GMR system is the GMR software. The GMR software provides both system configuration tools and system software functionality. Added to the program folder for a specific GMR application, the GMR system software controls input voting, special GMR memory mapping, diagnostic messaging, periodic auto-testing, and other operating features of the processor subsystem.
Just As following table display, GE Intelligent Platforms proposed systems with dual controller could meet specification requirement for certification (SIL 3) with proper input and output sub-systems.

4.2.3  The Input Sub-System

The input subsystem is the part of a GMR system that gathers input data and provides it to the PLCs.
The table below lists the maximum SIL rating that can be achieved for each GMR input subsystem configuration. Genius analog input blocks have fewer diagnostics and therefore require more redundancy to achieve the same Safety Integrity Level.

According to specification, we assume detector vendor will provide duplex detector for each measure point, in this project GE Intelligent Platforms offered 1oo2 for detectors.
Discrete Input Autotest
The autotest exercises the system inputs to be sure they remain able to detect and respond to actual inputs. Input Autotest accommodates both normally-closed and normally-open devices with the devices in either state. The test detects input failures that would result in a failure to respond. Discrete Input Autotest does not cause spurious outputs.
Operation of the input autotest is internal to each Genius block. After initiation by the Autotest Master PLC, the autotest requires no additional interaction with the PLCs. While it is completing the autotest process, a block continues to supply its last valid set of inputs instead of the physical inputs to the PLCs.
The block performs the following actions during an Input Autotest:
·        Power feed outputs (point 16) are pulsed Off.
·        Selected input channels are pulsed On
·        All associated inputs are checked for their ability to detect the On or Off state, as appropriate. A fault is reported if the correct state is not detected.
By allowing some inputs to be turned On, the Input Autotest checks for circuit-to-circuit shorts and also checks its own operation.
Line Monitoring for 16-Circuit DC Blocks
For applications such as Emergency Shutdown (ESD), normally-closed inputs are generally monitored for short circuits across the lines, since that represents a fail to danger condition (that is: trip is not detected). In general, these inputs are powered from +24V, and a field short to ground is interpreted as a trip condition.

For applications such as Fire and Gas Detection, normally-open DC inputs are generally monitored for open circuits on the lines, since that represents a fail to danger condition (that is: trip is not detected). In general, these inputs are powered from +24V, and a field short to +24V is interpreted as a trip condition.

4.2.4  The Output Sub-System

The output subsystem is the part of a GMR system that provides output data. As customer documents specified and to meet international safety system standards for SIL3/DIN AK6, GE Intelligent Platforms proposed T-Block normally de-energized output for safety system shutdown level 1/2 (Simplex actuator) and I-Block normally energized output for safety system shutdown level 3/4 (Simplex actuator).

Note: Simplex detector configuration is only permitted under IEC 61508 if the input device conforms with the requirements of IEC 61508 Part 2 Table 2 Architectural Constraints on Type A Safety Related sub-systems and Table 3 Architectural Constraints on Type B Safety Related sub-systems.
Discrete Output Discrepancy Reporting
Output discrepancy monitoring is the process of monitoring the block’s output voting to detect discrepant output data from the PLC processors.
All PLCs periodically monitor all blocks' discrepancy status. On interrogation by any PLC, the block responds with a discrepancy report message indicating any discrepant output and disagreeing PLC. If a PLC is sending discrepant output data to a block, the GMR system logs an output discrepancy fault in the I/O fault table and sets the appropriate fault contacts.
The GMR system performs output discrepancy checking whenever it is not performing input or output autotesting (between autotests during the autotest interval). It checks all output blocks in redundant output groups and any nonredundant output blocks marked for discrepancy checking in the GMR configuration.
If the GMR system determines that an output changed state during a discrepancy check, it attempts up to three times to properly complete the discrepancy check on an output block. This prevents logging false discrepancy faults that might be caused by the application program changing the state of an output while a discrepancy check is being performed
Output discrepancy checking works with outputs that change state less frequently than approximately once per 10 PLC scans. If an output changes state more rapidly than approximately once per 10 PLC scans, the results of output discrepancy checking for that output could be ignored. Nuisance discrepancy faults caused by transitioning outputs should NOT ever be logged.
A specific %M command bit (%M12266) can be used to enable/disable fault report information about rapidly-transitioning output discrepancies.
Discrete Output Autotest
Discrete output autotest checks the ability of outputs to respond to the commanded output state. It detects short circuit, open circuit, failed switch and other types of faults.
For discrete output groups, two types of faults may prevent the output autotest from completing for that output group and thus cause an I/O shut down for the outputs in the group. The faults are:
·         Loss of a block within the group (any failure that causes the block to no longer communicate on the Genius bus such as loss of power.)
·         Output autotest failure of a type that could potentially prevent a normally energized output from being tripped off. An example is the short of a source block output to +24 Vdc.
Output Autotest uses the standard Genius block Pulse Test feature. During testing, the system is online and available.
For the test to be performed:
·         All blocks in the group must be online.
·         There may be no I/O override applied to any block in the group.
·         For each block output in the group:
·         There may be no I/O force applied.
·         There may be no hardware fault (such as a failed switch).
·         For all outputs, the corresponding circuit of each block in the group must be in the same logical state.
The devices connected to the output circuits to be autotested must be able to withstand the On and Off pulse times discussed in this section. Note that actual times in an application depend on the presence of other scheduled tasks and on the configuration of the points.
Pulse testing occurs whether the output is in the On state or the Off state by executing one of two tests. These are the pulse ON-OFF-ON test and the pulse OFF-ON-OFF test. The following Pulse Test descriptions refer to Pulse Test operation of a block configured in the GMR mode only.
OFF-ON-OFF Test: The first ON pulse is for about 1.7mS. During this time, if the No Load diagnostic is enabled, the current data is checked and recorded. After this time, the test turns the point Off and the diagnostic, volts, and current data (if No Load is enabled) are checked. If the correct voltage and/or current data is NOT reported, the time constant is increased and the process repeats. If the correct voltage and/or current data is reported after any of the pulses, the test is passed and no further pulsing of the point occurs. The maximum number of pulses that can occur is 7, with a minimum duration of 1.7mS and a maximum duration of 20mS. Also, there is a delay of approximately 5 to 15mS until the same point is pulsed again. These times depend greatly on the configurations of the other points.
ON-OFF-ON Test: Similar activity occurs for this test. The initial time a point is Off is about 5mS. The only fault checked for in this case, however, is that the volts feedback agrees with the commanded state. If it does not, the point is pulsed Off again for about 7.5mS. A maximum of two pulses of approximately 5mS and 7.5mS duration can occur. The 7.5mS pulse occurs only if the volts feedback for the first pulse is incorrect.
The T-Block Output Group
For level 1/2, GE Intelligent Platforms offered a T-Block Output Group consists of two Genius 16-circuit source-type Genius blocks connected in parallel on one side of a load. The other side of the load is tied to ground. Although the illustration below shows just one load for a group of two blocks, a pair of 16-circuit blocks can control up to 16 loads.

Outputs of a T-Block Output Group are “normally-De-energized”. This type of group might be used in high-availability applications where it is necessary to be able to turn ON a critical load. Both blocks must be either 16-circuit or 32-circuit blocks. The two blocks must be connected to two different busses.
For a 16-circuit T-Block Output Group, Source Block IC660BRD020 has been used. This block has been designed for use in T-Block Output Groups. It has diodes integrated into the terminal assembly to prevent current feedback from keeping the block powered up, via output connections, when it has otherwise lost power.
Output circuits that are to be autotested must be able to withstand the On and Off pulse times used by the test.
I-Block Output Group.
For level 3/4, the I-Block output has been offered. An I-Block Output Group consists of a source-type Genius block connected to one side of the load and a sink-type Genius block connected to the other side of the load.
This type of group is most suitable for redundant shutdown applications. Both blocks in an I-Block Output Group will be 16-circuit blocks. The two blocks must be connected to two different busses. Although the illustration below shows just one load for a group of two blocks, a pair of 16-circuit blocks can control up to 16 loads.

An I-Block Output Group might be used in fail-safe applications where it is necessary to be able to turn OFF a critical load. If either block fails, the other can still turn the load OFF.
Output circuits that are to be autotested must be able to withstand the On and Off pulse times used by the test.

4.2.5  Genius IO Bus

Each PLC requires one to three Bus Controllers per redundant GMR bus. Larger systems may require more than one I/O subsystem. Each PLC may have up to 31 Genius Bus Controllers, in multiple racks. What was been represented below, there are 2 sets of triple Genius Buses, 6 Genius controller each has been inserted in CPU rack.  It will realize triple separate Analog input and help to meet SIL3.

4.2.6  Series 90 TCP/IP Redundancy

The Series 90 TCP/IP Triplex enabler allows HMI to interface to up to three GMR PLCs, with up to 2 network paths per device. With cabling redundancy, the Series 90 TCP/IP Triplex enabler communicates with the PLC using the first path while monitoring the second path. It switches automatically, without PLC intervention, to the second path if the first path fails. It continues to monitor the first path and automatically switches back to the first path on recovery. Cabling redundancy will be implemented with a redundant Ethernet LAN and one connection from each PLC to both of the Ethernet LANs.
Proposed system will be redundant CPU, the Series 90 TCP/IP Triplex enabler communicates with one CPU, but automatically switches to another PLC if communications from the first PLC fail. It continues to monitor the PLCs and automatically switches back to a higher-ranking PLC on recovery.

4.2.7  Hardware Detail Information

3.2. 
3.2.1. 
3.2.2. 
3.2.3. 
3.2.4. 
3.2.5. 
3.2.6. 
3.2.7. 

PLC Racks

IC697 racks are considered open equipment, and therefore must be installed within a protective enclosure.
·         Accepts all IC697 PLC module types
·         Rear mount racks mount in a 10" (254 mm) deep
·         enclosure (fans normally not required)
·         Front mount rack mounts in a standard 19" (480 mm)
·         rack (fans normally not required)
·         Accepts plug-in AC or DC IC697 power supply
·         Provision for two rack operation from single power supply
The Standard Nine-Slot Racks and the Five-Slot Rack for the IC697 programmable controller are used for all CPU and I/O configurations. Each rack has provision for one power supply at the leftmost module position; and either nine additional slot locations (nine-slot rack) or five additional slot locations (five-slot rack).
Overall rack dimensions are 11.15"H x 19"W x 7.5"D (283mm x 483mm x 190mm) for the Nine-Slot Rack and 11.15"H x 13"W x 7.5"D (283mm x 320mm x 190mm) for the Five-Slot Rack. Slots are 1.6" wide except the power supply slot which is 2.4" wide.
Two racks can be interconnected to share a single power supply for applications having extended I/O requirements. A Power Supply Extension Cable kit (IC697CBL700) is available for such applications. Each rack provides slot sensing for rack-type I/O modules designed for the IC697 PLC. No jumpers or DIP switches on the I/O modules are required for module addressing. In this project, we select nine-Slot Racks(IC697CHS790)

Power Supply (IC697PWR711)

·         Operation from 120 VAC, 240 VAC
·         Three output voltages, 100 watts total
ü  +5 VDC output up to 18 amps
ü  +12 VDC output up to 2 amps
ü  -12 VDC output up to 1 amp
·         Slide-in rack mount construction
·         Electronic short circuit overcurrent protection
·         Two rack operation from a single power supply
The 100 Watt Power Supply Module is a rack-mounted unit that plugs directly into a 48-pin backplane mounted connector in the leftmost slot in the rack. It provides +5 volt, +12 volt and -12 volt power, and logic level sequencing signals to the backplane.
This power supply may be used either in a single rack application, or may also be used to provide power to a second rack if the total load is within the supply rating. Interconnection to the second rack is through a prewired cable
This Power Supply Module can operate from either a 120 volt or 240 volt nominal line (this is jumper selectable, as illustrated on page 3). For these two ranges, the power supply can accept an input voltage range of from 90 to132 VAC or from 180 to 264 VAC, 47 to 63 Hz.
The power supply includes an electronic overvoltage protection circuit. This circuit will turn the output off if the 5 volt bus exceeds 6.2 +0.5 V. The power supply must be turned off to be reset. External overvoltage on the output that triggered the overvoltage protection will not cause the power supply fuse to open. However, if an internal fault in the power supply caused the overvoltage condition, the fuse may open. Replace this fuse with a 3AG 3 amp, 250 volt fuse.
The power supply provides electronic overcurrent protection for each of the 3 outputs. If the maximum current rating is exceeded, the voltage will collapse to a low value.
It will remain in that state until the load is either removed or reduced. A current overload (including a short circuit condition) will not cause the fuse to open.
This power supply does not comply with FCC requirements in non-industrial applications for conducted EMI on AC power lines.

PLC Controller – CPM790

Three models of the Series 90-70 PLC CPU support GMR: CPM 790, CPU 789, and CPU 788. The I/O capacity of the system depends on whether the CPU is a model 788, model 789 or model 790. Considered about to reduce the long-term system operation cost and system consistency, GE Intelligent Platforms proposed CPM790 for both ESD and FGS.
The CPM 790 is a single slot programmable controller CPU that allows floating point calculations. It’ main features includes:
·         Single slot CPU
·         Provides 1 Mbyte of battery-backed memory in the same slot (up to 512 Kbytes available for use by ladder diagram application program)
·         Supports floating point calculations
·         Up to 12K discrete inputs and outputs (any mix - simplex mode only); 2048 voted discrete inputs, 2048 voted discrete outputs
·         Up to 8K analog inputs (simplex mode only) and 8K analog outputs (simplex mode only); 1024 voted analog inputs
·         0.4 microseconds per Boolean function
·         64 MHz, 80486DX2 microprocessor
·         Supports IC660/IC661 I/O (and IC697 I/O in simplex mode only)
·         Programmed by MS-DOS_, or Windows_ software products running on Windows_ 95 or Windows NT_ over Ethernet TCP/IP or through the SNP port.
·         Configurable data and program memory
·         Battery-backed calendar clock
·         Three position operation mode switch
·         Password controlled access
·         Remote programmer keyswitch memory protection
·         Four status LEDs
·         Software configuration (No DIP switches or jumpers)
·         Reference information inside front door
·         In-system upgradeable firmware

Genius IO Bus and bus Controller

The proposed triple Genius bus is shielded twisted–pair wire, daisy–chained between devices, and terminated at both ends. Proper cable selection is critical to successful operation of the system. Conservative wiring practices, as well as national and local codes, required physical separation between control circuits and power distribution or motor power.
·         Bus Type: Daisy–chained bus cable; single twisted pair plus shield or Twinax. Fiber optics cable and modems can also be used.
·         Bus Termination 75, 100, 120, or 150 ohm resistor at both ends of electrical bus cable.
·         Baud Rate: Configurable.153.6 Kbaud standard, 153.6 Kbaud extended, 76.8 Kbaud, or 38.4 Kbaud.
·         Maximum Bus Length: 7500 feet at 38.4 Kbaud, 4500 feet at 76.8 Kbaud, 3500 feet at 153.6 Kbaud extended, 2000 feet at 153.6 Kbaud, standard. Maximum length at each baud rate also depends on cable type. Greater bus lengths are possible using sections of fiber optics cable with modems.
·         Maximum Number of Devices: 32 devices at 153.6 Kbaud standard, 153.6 Kbaud extended, or 76.8 Kbaud. 16 devices at 38.4 Kbaud. Includes bus controller and typically a Hand–held Monitor.
·         Data Encoding: Each bit is encoded into three dipulses, majority voted at the receiver to correct any single dipulse errors. A dipulse is an AC code consisting of a positive then negative excursion of voltage. Dipulses are individually sampled to reject low and high frequency interference.
·         Modulation Technique:Frequency Shift Keying (FSK) 0 to 460.8 KHz max. (153.6 Kilobaud)
·         Isolation: 2000 volts Hi–Pot, 1500 volts transient common mode rejection.
·         Signal/noise Ratio: 60 db
The Series 90_–70 PLC Bus Controller (catalog number IC697BEM731) is used to interface a Genius_ I/O serial bus to a Series 90–70 PLC.
The Bus Controller handles all data transfer between the PLC and the devices on its bus. In order to do this, the Bus Controller must interface two completely separate and asynchronous activities:
·         The Genius bus scan, a cycle of communications between the devices on a bus (including the Bus Controller itself). The cycle follows the order of Bus Addresses (0–31).
·         The CPU sweep, the cycle of actions that includes communications between the CPU and the Bus Controller.
The Bus Controller manages data transfer between the bus and the CPU by maintaining two separate on–board RAM memories. One interfaces with the bus and the other interfaces with the CPU. The Bus Controller automatically transfers data between these two memories, making data available to the bus or to the CPU when it is needed.

 

Ethernet Interface (IC697CMM742)

·         Connects IC697 PLC to an IEEE 802.3 CSMA/CD 10Mbps Ethernet LAN via one of three network ports: 10BaseT, 10Base2, or AUI
·         10BaseT and 10Base2 network ports provide direct connection to 10BaseT or 10Base2 network without an external transceiver
·         Standard 15-pin AUI network port allows choice of 10Base5, 10Base2, 10BaseT, 10BaseF, or 10Broad36 medium with user-supplied 802.3-compatible transceiver
·         Firmware is pre-loaded for easy installation and is maintained indefinitely; firmware is easily upgraded in-system from PC attached to RS-485 serial port
·         The Ethernet Interface provides:
ü  Data exchange using configuration-based and logic-based Ethernet Global Data
ü  TCP/IP communication services using SRTP
ü  Full PLC programming and configuration services
ü  Comprehensive station management and diagnostic tools
The IC697CMM742 Ethernet Interface (Type 2) provides high performance TCP/IP communications for the IC697 PLC.
The Ethernet Interface (Type 2) plugs into a single slot in an IC697 PLC rack and is configured with the IC641 PLC programming software. Up to four Ethernet Interface (Type 2) modules can be installed in an IC697 PLC CPU rack.
The Ethernet Interface (Type 2) contains three network ports: 10BaseT (RJ-45 connector), 10Base2 (BNC connector), and AUI (15-pin D-connector). The Ethernet Interface automatically selects the network port in use. One network port may be used at a time.
The 10BaseT network port permits direct connection to a 10BaseT (twisted pair) network hub or repeater without an external transceiver.The 10Base2 network port permits direct connection to a 10Base2 (ThinWire) network without an external transceiver. The AUI network port permits attachment of a user-supplied AUI (Attachment Unit Interface, or transceiver) cable.
The AUI cable connects the Ethernet Interface to a user-supplied transceiver that is directly connected to the 10Mbps Ethernet network. The transceiver must be 802.3 compatible and must have the SQE option enabled.

Genius IO--16 Circuit DC I/O Blocks

GE Intelligent Platforms has offered 16 circuits DC I/O blocks in this proposal. There are 3 kinds of blocks:
·         24/48 VDC Source block (IC660BBD020), for use with 3–wire solid-state sensors and electromechanical sensors, which provides current to field output devices.
·         24/48 VDC Sink block (IC660BBD021), for use with 3–wire solid-state sensors and electromechanical sensors, which receives current from field output devices.
·         24/48 VDC Source block (IC660BRD020), for use with 3–wire solid-state sensors and electromechanical sensors, which provides current to field output devices. Special use for “T” output.
Features
Genius 16 Circuit DC Input/Output blocks have 16 discrete circuits, each easily configured to be an input, tristate input, or output. Output circuits can be connected directly to input circuits without the use of other components or inversion of logic states. Control power is tapped off the input/output device voltages wired to the terminals. No separate block power supply is needed.
Configurable features include:
·         Output Pulse Test capability
·         Selectable Input Filter Time from 10mS to 100mS
·         Output powerup defaults
·         Output Hold Last State or default
·         CPU Redundancy type
·         Bus Switching Module control
The block’s advanced diagnostics can pinpoint causes of installation and run–time errors. Each circuit has electronic circuit protection that shuts down an output if inductive surge current exceeds 15 amps for more than 10mS. The output is easily restored by command from a Hand–held Monitor or the CPU.
Additional diagnostics of these blocks are:
·         Overtemperature Failed Switch
·         Open Wire for Tristate Inputs
·         Overload Detection and Shutdown
·         No–load Detection

Genius IO--DC 32-Circuit Source/Sink I/O Blocks

A DC 32-Circuit Source/Sink I/O Block is an intelligent, configurable module that interfaces the controller to devices that provide or accept a binary signal. The blocks are compatible with a wide range of input devices, including both 2-wire and 3-wire electronic proximity switches.
Outputs may be low-power control and indicating devices such as relays, contactors, and lamps. Two models are available:
·         12/24 VDC 32- Circuit Source block (IC66*BRD024), which provides current to field output devices.
·         5/12/24 VDC 32-Circuit Sink block (IC66*BRD025), which receives current from field output devices.
Features
·         Source and Sink versions each operate at nominal 12 to 24 volts DC
·         Sink version is also +5 volt TTL-compatible
·         Thirty-two configurable I/O circuits, inputs and outputs can be mixed on block
·         Resettable self-protecting circuits
·         Software configurable
·         Advanced diagnostics
·         Short circuit protection
·         Failed Switch detection
·         Blocking diodes and feedback resistors for redundancy applications
These blocks have 32 identical discrete I/O circuits, each easily configured to be an input, an output, or an output with feedback. This flexibility provides maximum design and application efficiency.
Each circuit contains built-in protection when used as an output, protecting the driver while allowing short-time surges. It also protects against shorted loads caused by wiring errors.
Block LEDs verify proper block operation and CPU communications. Individual circuit LEDs on the logic side indicate voltage present on inputs and outputs

VersaMax® Genius® Network Interface Unit

The Genius Network Interface Unit acts as controller for a set of I/O modules. Power for module operation is provided by a power supply that installs directly on the NIU
Specifications:

Number of modules	8 per rack, up to eight racks.
Network inputs per bus scan	128 bytes
Network outputs per bus scan	128 bytes
Discrete Input Memory	1024 points
Discrete Output Memory	1024 points
Analog Input Memory	128 bytes
Analog Output Memory	128 bytes
Power Consumption	+5V@250mA, +3.3V@10mA
Serial Bus Address	0 to 31
Network data rate	153.6 Kbaud extended, 153.6 Kbaud standard, 76.8 Kbaud, or 38.4 Kbaud.

 

VersaMax® Power Supply (IC200PWR002)

24VDC Expanded 3.3V Power Supply IC200PWR002 provides backplane power for CPU, NIU, and I/O modules. It supplies up to 1.5 Amps output current via 3.3 volt and 5 volt outputs, with up to 1.0 Amp on the 3.3 Volt output.
When mounted on the CPU or NIU module, this power supply serves as the main power supply for the station. It can also be used as a supplemental power supply when mounted on a Power Supply Booster Carrier.
Specifications:

Input Voltage	18 to 30 VDC, 24VDC nominal
Input Power	11W
Holdup Time	10ms
Inrush Current	20A at 24VDC 25A at 30 VDC
Output Voltage	5VDC, 3.3 VDC
Protection	Short circuit, overload, reverse polarity
Output Current Total 3.3VDC Output 5VDC Output	1.5A maximum 1.0A maximum (1.5A - I3.3V ) maximum

VersaMax® Analog Input Module, IC200ALG265

Analog input module IC200ALG265 provides an interface to 15 voltage inputs. Analog input module IC200ALG266 provides an interface to 15 current inputs. Both modules are rated for use in safety applications (meets the requirements of IEC61508, SIL2 for control failures during operation and SIL3 for avoidance of systemic failures during the different phases of the lifecycle).
No external power source is required for module operation. Power for the user’s transceivers must be supplied from an external source. Intelligent processing for this module is performed by the CPU or NIU. The module provides 15 words of analog input data.
Module Specifications:

Module Characteristics
Channels	15 single ended, one group
Isolation: User input to logic (optical) and to frame ground Group to group Channel to channel	250VAC continuous; 1500VAC for 1 minute   Not applicable None
LED indicators	OK LED
Thermal derating	None
Backplane current consumption, maximum	5V = 150mA, +3.3V = 50mA
External power supply	None
Input Characteristics
Input voltage, IC200ALG265	-10V to +10V
Input Fault Withstand	+/-30V
Input Impedance	100K Ohms
Accuracy at: 25 degrees C 0 to 60 degrees C	+/-0.3% typical of full scale, +/-0.5% maximum of full scale +/-1% maximum of full scale
Resolution, 15 bits	0.3125mV = 1 count
Filter response(3dB Corner Freq)	32Hz +/-20%
Update rate	7.5ms

4.2.8  Sequence of events (SOE) recording

SOE (Sequence Of Events) Logging will be accomplished using standard documented library functions on the GMR software CD. The SOE establishes the correct sequence of ten “current” events per user category, time and date stamps these from a possible 128 user assigned events. This table is reset from the user request, or may be automated for operation with SOE station or other device (like DCS or operating console).
Additionally, a “historical” log will maintain the last First Out events for the past 10 occurrences.
In order to establish a Sequential Order of Events when a trip, request, or shutdown occurs, an application program is available from GE Intelligent Platforms to store the information in the GMR CPUs . The date and time stamps can be read into a SOE station, or DCS asynchronously without concern for losing the sequence information.)
The SOE is a library module that is optionally included in the application program to establish Sequential Order of Events functionality. An event can be initiated by system logic, external user request, monitored system error, or any internal application program request.
The application program block stores its information in the PLC CPUs. The data and time stamps are logged along with the exact corresponding event, and may be read into a SOE station or DCS asynchronously without concern for losing the sequence information. It could be print out by matrix message printer in sequence or by report printer in customized report forms.

4.2.9  Alarm Display

GE Intelligent Platforms has offered some sets of Cimplicity PE HMI software. They will be installed on Engineering station/Operator station, used to configure, display and archive system/process/SOE alarm.

4.2.10        Time Synchronization

GE Intelligent Platforms GMR will use its integrated function block to receive real-time signal from the system master clock. It may be one of GMR controller or one of engineering station.
The system also can get real time signal from DCS or other external master clock through OPC/Ethernet, serial connection or Digital signals.

4.2.11        Serial interface technology

IC200CPUE05 provides two serial ports provide RS-232 and RS-485 interfaces for serial communications and a built-in Ethernet Interface. The RS-232 serial port can be configured for Local Station manager operation to provide access to diagnostic information about the Ethernet interface.
The two serial ports are software-configurable for SNP slave or RTU master or slave operation. 4-wire and 2-wire RTU are supported. If a port is being used for RTU, it automatically switches to SNP slave mode if necessary. Port 1 can also be configured for Local Station Manager operation to provide access to diagnostic information about the Ethernet interface. Both ports default to SNP slave and both automatically revert to SNP slave when the CPU is in Stop mode, if configured for Serial I/O. Either port can be software-configured to set up communications between the CPU and various serial devices. An external device can obtain power from Port 2 if it requires 100mA or less at 5VDC.
Port 1: is an RS-232 port with a 9-pin female D-sub connector. The pinout of Port 1 allows a simple straight-through cable to connect with a standard AT-style RS-232 port.
Port 1 can be configured for either CPU serial communications (SNP, RTU, Serial I/O), or local Station Manager use. If Port 1 has been configured for CPU use, it can be forced to local Station Manager operation using the Restart pushbutton. Once forced, Port 1 remains available for station manager use until the PLC is power cycled, or the Restart pushbutton is pressed.
Port 2: is an RS-485 port with a 15-pin female D-sub connector. This can be attached directly to an RS-485 to RS-232 adapter (IC690ACC901). Port 2 can be used for program, configuration.
 
 

·                     IO Requirements and Configuration

4.2.12        PCS IO Summary

	PCS
Signal Type	Requisition			Provided by JMT
	Qty.	Spare 20%	Total	Qty.	Spare Rate	IO Module Type	IO Module Qty.	Channel Qty Per IO
	Boiler
Signal Type	Requisition			Provided by JMT
	Qty.	Spare 20%	Total	Qty.	Spare Rate	IO Module Type	IO Module Qty.	Channel Qty Per IO

 
 

4.2.13        SIS IO Summary

Signal Type	Requisition			Provided by JMT
	Qty.	Spare 20%	Total	Qty.	Spare Rate	IO Module Type	IO Module Qty.	Channel Qty Per IO

 
 

4.3        System Architecture

 

4.3.1  Engineering Workstation

Ladder logic or high-level language that enables mathematical and process expression statements programming is utilized for the software of the system. The system is capable of implementing all control function required by the application. Where repeated subroutines or algorithms are frequently used, the software program has special modules already written so that these subroutines or modules do not need to be written repeatedly.
Software can be protected from unauthorized changes by the use of either key lock switches or passwords.
The processor can be able to execute commands using the following functions and parameters:
·           Mathematical functionality with both integer and real numbers
·           Relay logic’s including transitional inputs and latching outputs
·           Time delays and counters
·           Arithmetic, algebraic and trigonometric functions
·           Median select and median deviation
Engineering Workstation connects to physical I/O points and maintains the Process Database. A variety of tag types are available, including analog and digital inputs and outputs, calculations, alarms, totalizers, timers, continuous and statistical control functions, SQL commands, and more. The applications include real-time graphics, trending, reporting, batch, MES, and many others. Toolkits are available for custom block development.
Engineering Workstations will collect data from the PLC via the redundant Ethernet interface. Make sure that the data refresh cycle is less than 100ms.
·           Windows 2000/XP/2003/Vista based
·           SQL/ODBC interfaces for easy integration with relational databases
·           Advanced visualization (HMI)
·           Math, Logic and Supervisory control (SCADA)
·           User and role based node or domain linked security
·           Real-time and historical trending
·           Manual data collection and data management
·           Advanced alarming and alarm management
·           High performance and secure networking
·           Wizards maximize development productivity
·           Discovery and Automatic Configuration Tools
·           Graphic Dynamo Management
·           Recipe Handling
·           Run-time and remote configuration
·           ActiveX controls for database connectivity (VisiconX)
·           Time and event scheduling
·           Microsoft Visual Basic for Applications Integration (VBA)

4.3.2  Operator Workstation

Operator station is the standard thick client. It serves as a traditional PC-based client in that it is installed on the hard disk and accesses data from a local or remote computer. All applications can be run on operator station, including real-time graphics, trending, alarming and reporting. Plus, users can perform development online from each client, including building graphics and adding tags to local or distributed servers.
·           Windows 2000/XP/2003/Vista based
·           SQL/ODBC interfaces for easy integration with relational databases
·           Advanced visualization (HMI)
·           User and role based node or domain linked security
·           Real-time and historical trending
·           High performance and secure networking
·           Graphic Dynamo Management
·           Recipe Handling
·           Run-time and remote configuration
·           ActiveX controls for database connectivity (VisiconX)
·           Microsoft Visual Basic for Applications Integration (VBA)
 
 
 
 
 

4.4        Bill of Material

PCS  ( Centre Control Room)

Item	Name	Part No.	Description	Unit	Qty.
1	Controller Carrier		Controller Carrier, simplex or redundant, power monitoring	piece
2	I/O Carrier		I/O Carrier, 8 module with earth bar
3	R-HAND Extender		R-HAND EXT. CARRIER
4	Carrier Extender		Carrier extender, left hand
5	Extension Cable		Carrier extension cable, 0.85m
6	Power Supplier		C1D2 5A 12VDC & 5A 24VDC AC input P/S - Full temp range
7	Power Supplier		C1D2 10A 24VDC AC input P/S - Full temp range
8	Hybrid Controller		Hybrid Controller
9	Bus Interface Module		PAC8000 Ethernet BIM
10	Redundant AI Module		8-channel AI, 4-20mA with HART for 2-wire Tp
11	Terminal Board		16-pin Mass Termination Assembly (Div 2)
12	Redundant AI Terminal Board		Redundant AI Terminal Board
13	AI Module		8-channel AI, 4-20mA with HART for 2-wire Tp
14	Terminal Board		Field terminal, non-incendive, fused (Div 2)
15	Redundant AO Module		8-channel AO, with HART for 4-20mA
16	Terminal Board		16-pin Mass Termination Assembly (Div 2)
17	Redundant AO Terminal Board		Redundant AO Terminal Board
18	TC Module		4-channel THC/mV input
19	Terminal Board		Field terminal, thermocouple
20	Redundant TC Module		8-channel AI, 4-20mA with HART for 2-wire Tp
21	Terminal Board		16-pin Mass Termination Assembly (Div 2)
22	Terminal Board		Terminal Board
23	RTD Module		4-channel RTD input
24	Terminal Board		Field terminal, RTD
25	Redundant RTD Module		8-channel AI, 4-20mA with HART for 2-wire Tp
26	Terminal Board		16-pin Mass Termination Assembly (Div 2)
27	Terminal Board		Terminal Board
28	DI Module		16-channel DI, 24Vdc non-isolated, module powered
29	Terminal Board		Field Terminal, non-incendive, for 16 ch DI
30	DO Module		16CH DO 12-42VDC MODULE PWRD
31	Terminal Board		FLD TERM 16CH NA
			Software
Item	Name		Description	Unit
1	Programming Software		"Hybrid Workbench, 5000 IO"	set
2	HMI Devlopment		CIMPLICITY HMI Server 35,000 I/O D&R System
3	HMI Runtime		CIMPLICITY HMI Server 35,000 I/O Runtime System
			Integration
Item	Name		Description	Unit
1	Engineering WorkStation		DELL
2	Operator WorkStation		DELL
3	Server		DELL
4	Firewall		CISCO
5	Operator Colse		700（H）x750（W）x1000（D）
6	Comm. Management		16 ports
7	Cabinet		2100（H）x800（W）x800（D）
8	Network Cabinet		2100（H）x600（W）x1000（D）
9	Switcher		6 X RJ45, 2 x MM Fibro
10	Surge Protection		MTL
11	Relay		IDEC
12	Fibro			m
13	Accessory
14	Printer	LaserJet Pro P1606dn	HP
15	Dot printer		EPSON

PCS  ( BOILER Control Room )

Item	Name	Part No.	Description	Unit	Qty.
1	Controller Carrier		Controller Carrier, simplex or redundant, power monitoring	块
2	I/O Carrier		I/O Carrier, 8 module with earth bar	块
3	R-HAND Extender		R-HAND EXT. CARRIER	块
4	Carrier Extender		Carrier extender, left hand	块
5	Extension Cable		Carrier extension cable, 0.85m	块
6	Power Supplier		C1D2 5A 12VDC & 5A 24VDC AC input P/S - Full temp range	块
7	Power Supplier		C1D2 10A 24VDC AC input P/S - Full temp range	块
8	Hybrid Controller		Hybrid Controller	块
10	Redundant AI Module		8-channel AI, 4-20mA with HART for 2-wire Tp	块
11	Terminal Board		16-pin Mass Termination Assembly (Div 2)	块
12	Terminal Board		Termination Board	块
13	AI Module		8-channel AI, 4-20mA with HART for 2-wire Tp	块
14	Terminal Board		Field terminal, non-incendive, fused (Div 2)	块
15	Redundant AO Module		8-channel AO, with HART for 4-20mA	块
16	Terminal Board		16-pin Mass Termination Assembly (Div 2)	块
17	Terminal Board		Termination Board	块
18	TC Module		4-channel THC/mV input	块
19	Terminal Board		Field terminal, thermocouple	块
23	RTD Module		4-channel RTD input	块
24	Terminal Board		Field terminal, RTD	块
28	DI Module		16-channel DI, 24Vdc non-isolated, module powered	块
29	Terminal Board		Termination Board	块
30	DO Module		16CH DO 12-42VDC MODULE PWRD	块
31	Terminal Board		Termination Board	块
			Software
Item	Name	Part No.	Description	Unit	Qty.
1	Programming Software	8459-HC-50	"Hybrid Workbench, 5000 IO"	块	1
2	HMI Devlopment	IC647TDV935	CIMPLICITY HMI Server 35,000 I/O D&R System	块	1
			Integration
Item	Name	Part No.	Description	Unit	Qty.
1	Engineering/Operator WorkStation	T5500	DELL	台	1
2	Server	DELL R720	DELL	台	1
3	Firewall	ASA5510-K8	CISCO	台	1
4	Operator Colse		700（H）x750（W）x1000（D）	台	3
5	Cabinet		2100（H）x800（W）x800（D）	台	4
6	Network Cabinet		2100（H）x600（W）x1000（D）	台	1
7	Switcher	EL0602	6 X RJ45, 2 x MM Fibro	台	4
8	Relay	RJ2S	IDEC	个	160
9	Fibro			米	1000
10	Accessory			套	1

 
SIS

Item	Name	Part No.	Description	Unit	Qty.
1	Controller Chassis	IC697CHS790	Rack, 9 Slots, Rear Mount	piece	2
2	Power Supplier	IC697PWR711	Power Supply, 120/240 Vac,125VDC, 100 Watts	piece	2
3	Controller	IC697CPM790	GMR Redundancy CPU, 486, 2K Triplex (voted) I/O	piece	2
4	Ethenet Module	IC697CMM742	Ethernet Inferface for Series 90-70, Type 2.  The CMM742 no longer supports the AAUI/AUI interface.  If the AAUI/AUI is required, please contact GE Global Customer Care.	piece	4
5	BUS Controller	IC697BEM731	Series 90-70 Genius I/O Bus Controller	piece	6
6	Rack Colling	IC697ACC724	Rack Cooling Fan, 230 Volt	piece	6
7	Blank Slot	IC697ACC720	Blank Slot Filler, full slot rack (qty. 6)	piece	1
8	BUS Interface	IC200GBI001	REMOTE I/O Genius NETWORK INTERFACE UNIT	piece	9
9	Power Module	IC200PWR002	POWER SUPPLY WITH EXPANDED 3.3VDC 24VDC INPUT	piece	9
10	IO Carrier	IC200CHS022	Compact I/O carrier box style	piece	33
11	AI Module	IC200ALG265	Analog input 15 bit 0 - 10VDC voltage, 15 channel, TUV approved.	piece	33
12	DI Module	IC660BRD024	Genius 12/24VDC Source Block for Redundancy T Output Configurations	piece	16
13	DO Module	IC660BRD024	Genius 12/24VDC Source Block for Redundancy T Output Configurations	piece	6
			Software
Item	Name	Part No.	Description	Unit	Qty.
1	Programming Software	IC647MPP101	Logic Developer PLC Professional with Programming Cable with USB Hardware key	piece	1
2	GMR Configration	IC641SWP745	GMR Phase 4 System and Configuration Software	piece	1
3	HMI Developmet	IC647TDV700	CIMPLICITY HMI Server 700 I/O Development & Runtime System	piece	1
5	Hand-Held Monitor	IC660HHM501	Hand-Held Monitor includes Cable and Battery Charger	piece	1
6	Programming Cable	IC200CBL002	Cable from NIU to PC for configuration and upgrade.	piece	1
			Integration
Item	Name	Part No.	Description	Unit	Qty.
1	Engineering WorkStation	T5500	DELL	set	1
4	Operator Colse		700（H）x750（W）x1000（D）	set	1
4	Operator Colse		700（H）x750（W）x1000（D）	set	1
5	Cabinet		2100（H）x800（W）x800（D）	set	4
6	Switcher	EL0602	6电口,2光口(GE)	set	4
7	Surge Protection	IOP32	MTL	piece	312
7	Conditioning	MTL5575	MTL	piece	84
8	Relay	RJ2S	IDEC	set	96
9	Field Power Supply	IC690PRM240	220V AC/24 V DC, swtich power supply,40A(GE)	set	4
10	Redundency Module	IC690PRS040		set	2
11	Fibro			m	1000
12	Accessory			set	1

 

4.5        System load of controller CPU

4.5.1   SIS CPU loading

4.5.2  PCS System CPU loading

Module Type	PCS-HZ25-D8 DPP
	Period	Module	Module	No. of	Total	Total
	(sec)	PU	MU	Modules	PUs	MUs
I/O Module
Analog Module
Digital  Module
Regulatory Control
Device Control
Logic Control
Redundancy
Total Pus/MUs:
Max Pus/MUs:
CPU Loading:
Memory Loading
NOTE:
1. PU = Processing Unit per Control Cycle; MU = Memory Unit, Kbytes; PUs for any given CM = (PU per Cycle) / (Cycle Time, sec.)

 
 
 
 

4.6        System Component MTBF Data

4.6.1  SIS Component MTBF Data

Item	Order Number	Description	MTBF (Hrs)
		Analog input 15 bit 0 - 10VDC voltage, 15 channel, TUV approved.
		Cable from NIU to PC for configuration and upgrade.
		Compact I/O carrier box style
		CPU 128K user configurable user memory,  0.8MSEC/K Boolean one RS232, one RS485 serial ports and Ethernet port 10Mbit base T.
		REMOTE I/O Genius NETWORK INTERFACE UNIT
		POWER SUPPLY WITH EXPANDED 3.3VDC 24VDC INPUT
		Bus Terminator 150 Ohm (Qty 4)
		Block Puller
		Genius 12/24VDC Source Block for Redundancy T Output Configurations
		Genius 5/12/24VDC Sink Block for Redundancy T Output Configurations
		Hand-Held Monitor includes Cable and Battery Charger
		Replacement Battery, CPU & PCM (qty 2)
		Blank Slot Filler, full slot rack (qty. 6)
		Rack Cooling Fan, 115 Volt
		Series 90-70 Genius I/O Bus Controller
		Rack, 9 Slots, Rear Mount
		Ethernet Inferface for Series 90-70, Type 2.  The CMM742 no longer supports the AAUI/AUI interface.  If the AAUI/AUI is required, please contact GE Global Customer Care.
		GMR Redundancy CPU, 486, 2K Triplex (voted) I/O
		Power Supply, 120/240 Vac,125VDC, 100 Watts

 
Total System Failure Rate:

Qty.	Part. No.	M.T.B.F.(K Hours)	Failure Rate	Total Failure Rate

 
Fail Rate=1/Per Module's MTBF
ESD/FGS System MTBF= (1/7.529)*1000000*2= 265639.5272 Hours

4.6.2  PCS System Component MTBF Data

·         Module	·          MTBF Figure (years) @ ambient :				·           Number of Components
	·	·	·	·
·	·	·	·	·	·
·	·	·	·	·	·
·	·	·	·	·	·
·	·	·	·	·	·
·	·	·	·	·	·
·	·	·	·	·	·
·	·	·	·	·	·
·	·	·	·	·	·
·	·	·	·	·	·
·	·	·	·	·	·
·           RAILBUS	·	·	·	·	·

 
For control system, control system including 1 pair of redundant CPU module, X1 AI modules, X2 AO modules, X3 DI modules, X4 DO modules and X5 communication modules. The whole system of the average trouble-free time calculation as follows (because redundant processor module average trouble-free working very long hours, need not consider) :

 
means customer has module in stock and failed module can be replaced in 4 hours.

Location	System MTBF/Hours	Availability
HZ25-8 DPP
XJ24-3 DPPB
EN FPSO TOP SIDE
EP24-2 DPP	12231	99.9%
PY10-2 WHPA	31205	99.9%

4.7        Power Consumption

4.7.1  Power Consumption – PCS

NO	System hardware	QTY	consumption		heat radiating statistics
			NO	total	(BTU/hr)	(BTU/hr)
			(W)	(W)
1	EWs, OWs, Printers
2	Control System
3	Others
4	Total

 

4.7.2  DC 24V Power –SIS

·	·           Unit(mA)	·           Qty.	·           mA	·	·
·           DI (Loop Use)	·	·	·	·	·
·           DO (Spare)	·	·	·	·	·
·           AI (Loop Use)	·	·	·	·	·
·           DI Module Power	·	·	·	·	·
·           DO Module Power	·	·	·	·	·
·           AI Module Power(NIU PSU)	·	·	·	·	·
·           Communication Module	·	·	·	·	·
·           Relay (GEF)	·	·	·	·	·
·           DO(T/I) FIELD DEVICE	·	·	·	·	·
·           AI(3-Wiring) FIELD DEVICE	·	·	·	·	·
·           BHPM64 (1.35W)	·	·	·	·	·
·           Hirschmann OZD	·	·	·	·	·
·           Sub Total (mA)	·	·	·	·	·
·           Total (mA) With 20% Spare	·	·	·	·	·
·           PSU(40A)	·	·	·	·	·

 
24VDC Power Supply Summary:                        
SIS System Total 24VDC Power Supply (40A): 4
 

4.7.3  AC 220V Power – SIS

 

UPS Loads Summary(50% Spare has been included)
		Amps	VA
	CCR
	PC Workstation
	PC Server
	Monitor
	Ethernet Switch
	CCR Total

 
 
 

Non-UPS Loads Summary(50% Spare has been included)
	CCR

 

5        Typical Layout of Cabinets

PCS Cabinet Layout
 

SIS CPU Cabinet Layout
 

ESD/FGS IO Cabinet Layout

SIS IO Cabinet Layout
 
 
 

6        Engineering, Manufacture and Inspection

6.1        INTRODUCTION

6.1.1        Purpose of the Project Execution Plan (PEP)

The purpose of the PEP document is to communicate the project plan in a formal, approved document. The PEP outlines the execution plan and quality assurance for the project.

6.1.2        Maintenance of the Project Execution Plan

The PEP makes reference to a number of documents that provide the basis for executing this project. Examples of these project documents are the project schedule, scope of work, organizational chart, standard forms and logs, etc.
Some of these documents are developed during the initial phases of the project but are issued to the project participants after the PEP has been issued.
A Project Execution Plan revision record is included at the front of each printed issue of the PEP.

6.1.3        Contents of the Project Execution Plan

The table of contents outlines the contents of Project Execution Plan (PEP). Each section will generally correspond with a heading in the actual PEP developed for the Project.

6.1.4        Management Statement

The Project Manager has a single point responsibility for ensuring that the quality of design, equipment, materials and construction meets the contract requirements, applicable standards and sound engineering practice.
The project team will be organized in such a way that responsibility for quality of project elements is clearly defined. Each planned quality activity will be the responsibility of a single person.

6.1.5        Distribution of the Project Execution Plan

The Project Execution Plan for this project will be distributed to the stakeholders of the project:

6.1.6        Authorization and Re-issues

This Project Execution Plan is originated and issued by the Project Manager. The Program Manager has authorized it for implementation. The Quality Assurance Manager shall review the Project Execution Plan on its quality aspects.
Re-issues of this Project Execution Plan shall be approved by the OTR Leader (China) and reviewed by the Quality Assurance Manager.

6.1.7        Indoctrination

At the beginning of the project, the Project Manager will instruct all key personnel assigned concerning the following aspects:
Scope of work and form of the contract
Specific quality requirements
Information concerning the project teams
Process Management
Information concerning city and location of the installation
Focal points of the project
Planning with milestones dates
Responsibilities
Meeting, reporting and communication
Project cost and extra work
Visits to Client's office site and third parties
 

6.2        PROJECT INSTRUCTION

During the implementation of the project there may be a need to add additional rules, procedures and/or information. These data will be issued as project instructions, which will be distributed to the project team with summary list indicating number and date of issue. The project instructions shall be read and followed.

6.2.1        Project Implementation Schedule (example)

 

	Project Schedule Templates	1	2	3	4	5	6	7	8	9	10	11	12	13	14
1	Define
1.1	Contract Effectiveness
1.2	Internal Project Handover
1.3	Internal Kick off Meeting
1.4	Kick off Meeting
1.6	Meeting Clarification for Design
2	Design
2.1	Function Design Specification
2.2	Meeting Clarification for Design
2.3	Updated Function Design Specification
3	Development
3.1	Detail Design Specification
3.2	Meeting Clarification for Design
3.3	Updated Function Design Specification
3.4	GE product procurement
3.5	Outsourcing Product procurement
3.6	PLC program development
3.7	HMI graphic Development
3.8	3rd interface development
3.9	Data Report
3.10	System integration
4	Test
4.1	Internal Integration Test
4.3	Factory Acceptance Test
4.5	Deliver
5	Deploy
5.1	Site Installation
5.5	Site Wiring
5.6	Power up and IO checking
5.7	Site Acceptance Test and Commissioning
5.8	Sustained performance test

This is a draft schedule, and it will be finalized during the kick off meeting.

6.2.2        Contract Variation

Contract variations shall be handled according to procedure.
Pricing and payment for project scope changes shall be prepared and signed by both the client and GEIP's project managers.

6.3        PROJECT EXECUTION STRUCTURE

GEIP will provide a highly skilled team of engineers for this project. GEIP project team will work with project team to establish a Functional Design Specification (FDS) for The Central Control System Integration with establish standards and concepts that will ensure the necessary interoperability of all systems and devices.
A project organization chart outlines management and technical lead for project implementation and their responsibilities. The project organization in the following section presents the project team with general areas of responsibilities and expertise.

6.3.1        Coordinated Project Organization

The project team key personnel consists of a Project Manager, a Lead Engineer, Description of Roles and Responsibilities
Project Manager
·           Responsible for all aspects of project implementation and is the primary contact for the Client
·           Lead project kick-off meeting
·           Manage cost controls, billings and change orders
·           Development and control of implementation schedule
·           Development of training plan
·           Develop site support plan
·           Ensure compliance with commercial terms
·           Administrative requirements of the project team
·           Approve man-hours and direct costs charged to the project account
·           Approve project staff assigned and appraises their performance
·           Instruct key members of the project team on subjects like communication,
·           Coordination and procedures
·           Establish the overall planning and sets priorities
·           Approve design changes, contract variations and extension/reduction of scope both with the Client and within Emerson
·           Monitor project progress and preparation of monthly progress report
·           Instruct engineers to take appropriate action to avoid delay
·           Report to the Program Manager
Quality Assurance Manager
·           Responsible for QC of the entire project
·           Interface to client and End-user as required for QC issues.
·           Report to the Project Manager
Lead Engineer
·           Primary contact for client for technical issues and changes
·           Responsible for the development of system design and implementation such as Hardware/software engineering, programming, assembly, wiring, documentation, testing and purchasing of equipment
·           Responsible for coordinating all third party products and engineering requirements, directing the special engineering efforts for buyout equipment, drafting, and technical documentation
·           Ensure that the system meets specification, the required functionalities and schedule of implementation as well as obtaining approval of the design
·           Delegate work to the project engineers allocated to the project
·           Provide technical assistance and training to the Project Engineers. Instruct his team members on the execution of their work and working methods to be applied
·           Appraise the performance of his team members
·           Report to the Project Manager
Project Engineer
·           System hardware and software engineering design, implementation and testing
·           Responsible for system integration
·           IO assignment and serial communication interface
·           Cable scheduling and cabinet layout
·           Hardware and cabinet wiring, staging and testing
·           IO database entry
·           Typical Logic design
·           Graphic display configuration
·           Software configuration and test
·           Factory Acceptance Test
·           System Integration Test for the integrated system
·           Assistance of site services
·           Report to the Lead Engineer
Project Administrator
·           Administrate man-hours utilization and project expenses
·           Forecast and monitor expenditures
·           Monitor and administer all Clients’ invoicing
·           Process and track all orders
·           Coordinate shipping requirements with factory and the Client
·           Prepare all inward and outward shipping documents
·           Coordinate goods inspection, packing and delivery
·           Report to the Project Manager
 

6.4        COMMUNICATION

All official contacts and correspondence with the package contractor will be via the GEIP Project Manager for all matters. It is, however, direct discussions between GEIP's and contractor's engineers can be arranged for technical related issues. Minutes of Meeting of such discussion shall always be approved and issued by Project Manager.

6.4.1        Correspondence Identification

For identification of correspondences, all correspondences to the Customer whether by fax or letter shall be dated and shall have the following reference number:
XX-YY-ZZZZ
Where:     XX denotes
"F2" for Fax
"L2" for Letter Memo
"MY for Minutes of Meeting
"RY for Progress 1 Status Report
"T2" for Transmittal
YY denotes year in last two digits
ZZZZ is a sequential number starting from 0001
All official correspondences shall be by fax or letter. Project and technical issues that need confirmation and approval are classified as official correspondences.
 

6.4.2        Correspondence and Telephone Communication

The Project Manager will distribute incoming correspondence via the Project Administrator (who registers and files) to the Lead Engineer, who will further distribute within their discipline.
The Project Manager will indicate who has to take action and which persons will receive the documents for information. All outgoing letters need the signature of the Project Manager. The Project Manager shall check outgoing email and fax messages.
Telephone conversations with Client shall be reported to the PM by a telephone report, execution of the results needs approval of the PM. All documents will be provided with the GEIP's Project Number.

6.5        Meeting

6.5.1        External Meeting

Project team members have to inform the Project Manager and the Project Administrator in advance of date and place of external meetings with the client or others.
Date of external meetings with the clients hall be confirmed in advance in writing. The Project Administrator will therefore maintain a list of the external meetings.

6.5.2        Internal Meeting

Project team members will conduct weekly internal meetings on each Friday. The Project Manager, Lead Engineer and Project Engineers will attend the internal meeting. The internal meetings shall address at least the following:
·          Progress of scheduled work
·          Technical issues / problems
·          Information required from others
·          Team development issues

6.5.3        Minutes of Meeting

Minutes will be made of every external meeting. If possible draft minutes shall be made and agreed by both parties during the meeting. Typed minutes signed by GEIP Project Manager will be issued within three (3) working days after meeting.
Minutes for all meetings shall include:
Meeting reference number
An item number for each topic A description of each topic
"Action by" with due date indicated where required
"Info" indicated if no action required
Client's Project Manager may comment on minutes within three (3) working days. The minutes shall also be approved and signed by client's Project Manager and return to GEIP. In case no comment is received from the client within three (3) working days after issuing, the contents are assumed being approved by the client.
A list of outstanding action items shall be extracted from previous minutes of meeting and reviewed at each meeting with the client. This list will be registered during the meeting re-issued as an attachment to the minutes of that meeting.

6.5.4        Progress Report

Progress report will be produced and issued on a bi-weekly and monthly basis to client.
Bi-weekly report will include the followings:
Progress Summary
Critical Issues & Concerns
Monthly report will include the followings:
Progress Summary (Planned1 achieve activities)
Major Activities for the month
Manufacturing Progress & Status
Critical Issues & Concerns
Document Received & Submitted Status
Change Request Status and Progress (If any)
Billing & Payment Status (Planned/Actual)
Project schedule (If updated)
Planned activities for the following month
 

6.6        PROJECT CONTROL

6.6.1        Cost Control

The Project Administrator will prepare and submit a detailed project costing report to Project Manager monthly in order to establish forecast and to give Project Manager the opportunity to take corrective action as and when required.
The Project Manager will review the spent man-hours and expenses and discuss over and under runs with the team members concerned.
The Project Administrator shall in co-operation with the specialists estimate the contract variations and design changes and incorporates the pending and approved contract variations in the summary of contract variations to be issued monthly.

6.6.2        Scheduling and Progress Control

The Project Manager will coordinate the planning, scheduling and progress measurement activities. The planning, scheduling and progress control system consists of:
An overall project schedule
Document control records
Project Progress Report
Schedule Control
On a monthly basis, the Project Manager, in close co-operation with the team members, shall update the planning. The planning has to be a controlling tool and any experienced or anticipated variations have to be analyzed carefully by the Project Manager.
This can result in additional manpower or rearrangements of priorities. Review meetings will be held when necessary, during which actions will be initiated and reported.
Progress Reports
Progress reports will be prepared on a monthly basis and issued to EP not later than 10th of each month:
Progress this period
Forecast coming period
Overall project schedule
Contract variations /Design changes

6.6.3        Risk Control

The project management team shall as an on-going identify and control risks to the project. Once identified, these risks will be recorded; analyzed and contingency plans are prepared.

6.6.4        Quality Audit

A system for quality auditing has been established; the purpose of the quality audit is to verify that the quality system, which is established in accordance with the requirements specified in this project implementation and quality plan, is implemented and effective.
For this project, the internal audit activities exist of:
Review Project Execution Plan
Third party suppliers will be audited to ascertain their quality practices are sufficient to guarantee quality compliance on the project
The Quality Assurance Manager performs the audit and the Client may review the reports of quality audits
 

6.7        Inspection and acceptance testing

All hardware components to be supplied are tested in the course of production. The integrated systems are subjected to an additional total test after their assembly. Before system is ready for Factory acceptance, GE IP will perform a 100% system application function test and it would be recorded for each functions.

7        Acceptance

7.1.1        Factory acceptance test (FAT)

Included in the quotation price is a factory acceptance test of the central control systems. The purpose of this test is the verification of the completeness of the delivery and the system functions. In addition, the quotation includes an acceptance test of the system-specific configuration, in which the individual devices are simulated. For devices, status signals are set automatically after a delay, so that, for example, motors and valves can be switched realistically on screen.
The first part of the installation test includes a validity review of the technical documentation for the deliverable system (with regards to the system, not the task to be fulfilled) and an inspection of all contract-specific components installed and connected by standard methods. Presence, correct equipment Condition and Function (incl. project-specific bridge assignments).
The installation test is completed with a hardware test and a software test.

7.1.2        Site acceptance test (SAT)

Following assembly and installation of the complete system, its proper function will be verified.
A log will be generated, in which any errors are recorded.

8        Responsibility And Guarantee

8.1              Responsibility

JMT  will  be  responsible  for  the  complete  design, equipment purchasing, manufacture, inspection and testing, certifying, shipment,  installation  guidance,  commissioning  on  site  and  post-sale service  for  all  supplied  goods. JMT will accept necessary and feasible change request to the technical specification of the Goods as per customer’s requirement during the project execution period.
The Goods provide by JMT will be full compliance with all applicable project specifications, datasheet, drawings, codes, standards and the requirements of the certifying agency.
The ISO9001 QA/QC document(s) and the certificate(s) of the Goods issued by certifying agency for JMT and its sub-SUPPLIER(s) will be as attached in the tender documents.
JMT provides a list of the past application of their system for the offshore platform as attached. The integration of PCS, ESD and FGS in those applications will be explained in details.
JMT post-sale service offices will be listed as below.

8.2              Technical Service

JMT’s technical service will include project meeting, system design and configuration, technical training, FAT, shipment, installation guidance, SAT, start-up guidance, system delivery, quality assurance, technical document delivery and support service, etc. In project period, JMT will provide technical document according to customer’s requirement with DWG and PDF.

8.3              Warranty

JMT will warrant the satisfactory performance, reliability and maneuverability at the specified operating conditions of the Goods.
Quality Assurance Program 
JMT will provide a comprehensive quality assurance program for the customer’s approval. The quality assurance program will permit the quality inspector assigned by the customer to inspect the manufacturer’s factory and test the Goods under the JMT’s arrangement.
Function Test 
JMT will insure the Goods pass 100% function test before the final assembly. The function test will be described and recorded for the customer’s review and acceptance. JMT will re-test the products bought from others and submit the original test procedure and records of its manufacturer.
Any necessary modification to the approved design will comply with the requirements of the customer. JMT will, at no cost to the customer, modify or revise the design and promptly carry out fabrication re-work as may be required.
JMT will guarantee that the engineering, workmanship and materials of Goods will meet the design conditions on site.

8.4              Warranty Period

JMT will provide warranty for the Goods for a period of eighteen (18) months from the date of actual start-up of the Goods after commissioning and acceptance of customer, or twenty-four (24) months from the date of Goods’ arrival to the destination, whichever occurs first.

8.5              Post-Sale Service

JMT will provide local post-sale service for all supplied Goods through on-site technical support or telephone support.
JMT has Service center facility in Shanghai/Beijing/Guangzhou/Global; we can provide all JMT project/ products service, and professional services for project/products planned for this project from these locations.  JMT also provide consultant /application /engineering and integration /training /commissioning and startup etc. services from these locations.
On-site support:
JMT provide 7*24 service, the engineer can arrive site within 12 hour after receiving the on-site service request.
GE IP Telephone Support:
China: 400-810-7088 or contract JMT Project Manager
Global: 780-420-2000 or contract JMT Project Manager
Email: support.cn.ip@ge.com
JMT Telephone Support:
86-755-86022885

9        Preparation for Shipment

Equipment will be properly protected against shock, vibration and environmental conditions, all lifting points shall be clearly marked.
All provided cabinets will have   equal high performance as Rittal.
Preparation for shipment will refer to the Commercial Requirement in Bidding Documents regarding detailed shipping instructions, and meet the following requirements.
Shipping loose items for field assembly/installation will be separately in waterproof boxes with tag numbers, delivery lists and assembly drawing/procedure.  And the boxes will be noted with  "FOR  FIELD ASSEMBLY".
One-year spare parts will be separately packed/crated in waterproof boxes with tag and delivery lists, and separated from all start-up and commissioning parts.
All spare parts will be properly protected for a long-term storage condition.

10    Training

JMT Will provide 15 days local engineer training for 45 persons and 7 days local operation training for 30 persons.

11    Project Organization Chart and Resume of PMT

 
 

12    Technical deviation and discrepancy

Item No.	Name of Goods	Ref. No	Specifications Required	Specifications Provided	Deviation	Remarks
1	none
2

 

13    Appendix 1: Reference List

13.1    GMR

In China:

China/Area	Enduser	Product	Application	Industry	Date
	ShanDong Shida Science and Technology Petro-Chemical Co., LTD	GMR（Triplex）	1 MM tons/annual HeaveOil  ITCC	Petro-Chemical
	ShanDong Shida Science  and Technology Petro-Chemical Co. , LTD	GMR（Triplex）	100×104t/a Gasoline-Diesel by hydrogenation 20000Nm/h Make Hydrgen SIS	Petro-Chemical
	ConocoPhillips Penglai 193 WHPA Retrofir	GMR（Duplex）	ESD and F & Gas	Petro-Chemical
	Sinopec Beihai Branch	GMR（Duplex）	The lock hopper Control System	Petro-Chemical
	Sinopec Jiujiang Branch	GMR （Duplex）	The lock hopper Control System	Petro-Chemical
	GuangZhou Pu Hua Chemical Co. , LTD	GMR（Duplex）	250K tons/annual Chemicals SIS system	Chemical
	Inner Mongolia	GMR（Triplex）	Methanol/aroma Hydrocarbon SIS system	Chemical
	Luoyang Refining & Chemical HTC industrial Co., LTD	GMR（Triplex）	100K tons/annual the mixed carbon four cleavage SIS system	Petro-Chemical
	Maoming Hua Yuehua Petrochemical Co. Ltd	GMR（Triplex）	150K tons/annual Impregnant project SIS system	Chemical
	Shanxi Xiangyu Chemical Co., Ltd.	GMR（Duplex）	40K tons rubber auxiliary project SIS system	Chemical
	Rhodia fly Fine Chemical Co. Ltd.	GMR（Duplex）	DMAPA Project SIS system	Chemical
	Shanxi Yongxin Coal Coking Co., Ltd	GMR（Duplex）	60K tons/annual synthetic ammonia SIS system	Chemical
	Daqing Oilfield	GMR（Triplex）	Daqing Oilfiled Nanba LNG ESD	Petro-Chemical
	DongFang Steam Turbine Works	GMR（Triplex）9 sets	Turbine ETS system (9 sets)	Power
	Dong Fang boiler works	GMR（Triplex）2 sets	FSSS	Power
	Sichuan Da Xing Energy	GMR（Duplex）	Da Xing 200K tons methanol ESD	Chemical
	Shandong Xintai United Chemical	GMR（Triplex）	Phthalic Anhydride SIS system	Chemical
	Iraq halfaya Oilfield	GMR（Triplex）	Crude Oil processing station ESD	Petro-Chemical
	Chengdu cryogenic air separation	GMR（Duplex）	SiChuan Guangyuan Cangxi Datong 1MM cube LNG	LNG
	Chengdu cryogenic air separation	GMR（Duplex）	Chongqing Songzao-E future Co.,LTD LCMB	LNG
	LiaoNing Fushun Petro-Chemical	GMR（Duplex）	BMS	Petro-chemical
	Shanghai Gaoqiao Petro-Chemical	GMR（Duplex）	BMS	Petro-Chemical
	SinoPec Changling Branch	GMR（Duplex）	BMS	Petro-Chemical
	CNPC LiaoYang Petro-Chemical Alkene ESD	GMR（Duplex）	Hydrocarbon-Alkene ESD	Petro-Chemical
	Sinopec Zhongyuan OilField refine	GMR（Duplex）	250K tons/annual Catalytic gasoline hydrogenation ESD	Petro-Chemical
	HeBei Xintai Xuyang Chemical Plant	GMR（Triplex）	HeBei Xingtai Benzene benzene hydrogenation	Chemical
	Henan Province First Chemical Technology Co., Ltd.	GMR（Duplex）	300K tons Coal tar hydrogenation	Chemical
	Yunnan tianhua international engineering company	GMR（Duplex）	Yunnan YutianHua fertilizer PhaseII ESD	Fertilizer(synthetic ammonia)
	Shandong Xinlong Group		Shangdong XinLong 200K tons/annual Ion-exchange retrofit membrane	Chemical
	QingHai S Lake Industry Group Co.,Ltd		Synthetic ammonia/urea ITCC control	Chemical
	Shaanxi yanchang petroleum chemical engineering Co.,Ltd.		acetic acid ESD	Chemical
	Shaanxi coal industry group		Shanxi Coking ESD Project	Coal chemical
	Dongfang Electric Corporation Limited)		Dongfang Electric CO. Turbine Control	Power
	Zigong Honghe chemical company		SiChuan ZiGong PCE Project ESD	Chemical
	Datang Inner Mongolia coal gas)		Inner Mongolia Making Gas from Coal ITCC	Coal chemical
	Shanxi Shenmu MeifuYou Chemical		Shanxi Shenmu MeifuYou Chemical	Coal chemical
	Anhui wanwei chemical Group		Organic Compounds factory ESD	Chemical
	SHANDONG SHIDA SHENGHUA CHEMICAL GROUP		0.2M Ton/Y C4 ITCC Project	Oil & Gas
	Shanghai Shengbang		200K tons/annual Solvent naphtha SIS	Oil & Gas
	Shaanxi Xingping chemical fertilizer plant		Shanxi Xingping chemical fertilizer Plant(300K tons ammonia, 300Ktons methanol)	Chemical fertilizer
	Qingdao iron and Steel Group, Yanzhou coking plant		100K Ton/Y Carbinol ESD Project	Coal chemical
	Vietnam run Creek power plant		FSS	Power
	Sichuan air separation and gas company		Inner Mongolia Erdos 300K cube LNG	LNG
	Chengdu cryogenic air separation	GMR（Duplex）	Shanxi Jincheng Anthracite Mining Group LNG	LNG
	Sichuan air separation and gas company	GMR（Duplex）	Inner Mongolia Bayan Leer LNG	LNG
	Xinjiang Tarim Oilfield 2	GMR（Duplex）	Tarim Kela2 fire extinguishing system retrofit FGS	Oil & Gas
	CNOOC Chunxiao wellhead platform	GMR（Duplex）	ESD	Oil & Gas
	Turkmenistan Natural gas purification plant	GMR（Duplex）	Fire & Gas	Oil & Gas
	Yanshan Petrochemical granulator	GMR（Duplex）	ESD	Oil & Gas
	Shanghai refinery ESD retrofit	GMR（Duplex）	ESD	Petro-Chemical
	Yunnan Yuntianhua international chemical fertilizer of Qinghai Limited ESD	GMR（Duplex）	ESD	Chemical Fertilizer
	Shaanxi Yulin Yanchang Petroleum	GMR（Triplex）	ESD	Ethylic acid
	Wuhan Iron and Steel Corporation benzene hydrogenation ESD	GMR（Triplex）	ESD	Coal chemical
	Xinjiang Tarim Oilfield	GMR（Duplex）	Fire & Gas	Oil & Gas
	Dongfang Steam Turbine Works	GMR（Triplex）	Turbine ETS (4 sets)	Power
	Ningxia Green Energy Development Co., Ltd.	GMR（Duplex）	ESD	Air Separation
	Shaanxi Xingping chemical fertilizer plant	GMR（Triplex）	Synthetic ammoniaTurbine Control	Chemical fertilizer
	Sichuan air separation and gas company	GMR（Duplex）	NingXia clearer energyPhase II 300K cube LNG	LNG
	Chengdu cryogenic air separation	GMR（Duplex）	Shanxi Yigao LNG（600K cube）	LNG
	Hebei Xingtai Jiantao Co.,LTD 50K tons benzene hydrogenation ESD	GMR（Triplex）	ESD	Coal Coke
	Kunming steel works 50K tons benzene hydrogenation ESD	GMR（Triplex）	ESD	Coal Coke
	Hebei Xingtai Xuyang Co.,LTD 100K tons benzene hydrogenation ESD	GMR（Triplex）	ESD	Coal Coke
	Anshan Steel Corp 150K tons benzene hydrogenation ESD	GMR（Triplex）	ESD	Coal Coke
	Anshan Energy Institute 100K tons benzene hydrogenation ESD	GMR（Triplex）	ESD	Coal Coke
	QingHai Salt Lake Industry Group Co.,Ltd Turbine Control	GMR（Triplex）	1MM tons potash fertilizer Turbine Control	fertilizer（ammonia，Urea）
	CNPC Southwest gas field  gas field	GMR（Duplex）	Fire & Gas	Oil & Gas
	Shanghai natural gas Co.,LTD	GMR（Duplex）	Fire & Gas	LNG
	Dongfang Steam Turbine Works	GMR（Triplex）	Turbine ETS (4 sets）	Power
	Deyang Hongrun light hydrocarbon Chemical Co., Ltd.	GMR（Duplex）	ESD	Petro-Chemical
	CNPC Southwest gas field  gas   field Longgang purification plant	GMR（Duplex）	Fire & Gas	Oil & Gas
	Guangdong Dongguan Jiufeng Liquefied Gas Co. Ltd	GMR（Triplex）	Tank farm ESD	LNG
	China University of Petroleum (East China)	GMR（Triplex）	Sub-Sea Blow-Out Prevention Control System(	Oil & Gas
	Xinjiang Tarim Oilfield Kela	GMR（Duplex）	Fire & Gas	Oil & Gas
	Hebei Huayue Fine Chemical Co., Ltd.	GMR（Duplex）	300K tons/annual Diesel oil hydrogenation ESD	Petro-Chemical
	Hebei Dagang Petrochemical Co., Ltd.	GMR（Duplex）	300K tons/annual catalytic cracking	Petro-Chemical
	Shanxi Shenmu Petrochemical Company Limited		Coal tar hydrogenation ESD	Coal Chemical
	Sinopec Yanshan petrochemical		100 tons/day methanol make hydrocarbon ESD	Petro-Chemical
	Zhejiang Jinke hydrogen peroxide Co. Ltd.		Hydrogen peroxide ESD	Chemical
	Taicang Plastic Additives Factory Co., Ltd.		5000 tons/annual dicumyl peroxide ESD	Chemical
	Taian Boda Chemical Petrochemical Co. Ltd.		Hydrogenation of hydrogen production ESD	Chemical
	Hongkong Jiu source chemical		Sichuan Dazhou 450K tons ammonia，700K tons urea ESD	Chemical fertilizer
	Sichuan air separation and gas company		GanSu Province LNG ESD	LNG
	Chengdu cryogenic air separation		Shanxi Jincheng LCBM ESD	LCMB(LNG)
	Sichuan air separation and gas company		Inner Mongolia Erdos LNG ESD	LNG
	Chengdu cryogenic air separation		Anhui Province LNG ESD	LNG
	Sichuan air separation and gas company		Sichuan Longquan Yonglong LNG ESD, 135K cube	LNG
	Sichuan air separation and gas company		Ningxia cleaner energy 100Kcube LNG	LNG
	CNPC Chongqing Gas Station Longmen ESD Project		Nature gas wellhead gas station ESD	Oil & Gas
	Sichuan Sheng Ma Chemical Co. Ltd. Xinying Petroleum asphalt plant		1MM tons/annual atmospheric and vacuum distillation unit & 200K tons/annual catalytic cracking	Petro-Chemical
	Shandong Yanzhou Mining Bureau Lunan Chemical Fertilizer plant		Vaporization furnace	Chemical
	Sinopec Yanshan  chemical plant 7	GMR（Duplex）	Methanol making hydrocarbon Test Platform	Petro-Chemical
	ConocoPhillips Penglai 193 WHPD platform	GMR（Duplex）  2 sets, one is ESD, the other is FGS	ESD  and F & Gas	Oil & Gas
	ConocoPhillips Penglai 193 WHPE platform	GMR（Duplex）  2 sets, one is ESD, the other is FGS	ESD and F & Gas	Oil & Gas
	ConocoPhillips Penglai 193 WHPF platform	GMR（Duplex）  2 sets, one is ESD, the other is FGS	ESD and F & Gas	Oil & Gas
	ConocoPhillips Penglai 193 FPSO	GMR（Duplex）  8 sets,  ESD and FGS	ESD and F & Gas	Oil & Gas
	India Amarkantak	GMR（Triplex） 2 sets	Amarkantak 2x300MW turbine ETS	Power
	India Sagardighi	GMR（Triplex） 2 sets	Sagardighi 2x300MW turbine ETS	Power
	India Durgapur	GMR（Triplex）	Durgapur 1x300MW turbine ETS	Power
	India Barmer	GMR（Triplex） 10 sets	Barmer 10x135MW turbine ETS	Power
	India Nagarjuna)	GMR（Triplex） 2 sets	（Nagarjuna) 2x600MW turbine ETS	Power
	Penglai 193 WHPC platform	GMR（Duplex）  2 sets, one is ESD, the other is FGS	ESD and F & Gas	Oil & Gas
	Penglai 193 WHPB platform	GMR（Duplex）  2 sets, one is ESD, the other is FGS	ESD and F & Gas	Oil & Gas
	Penglai 193 RUP platform	GMR（Duplex）  2 sets, one is ESD, the other is FGS	ESD and F & Gas	Oil & Gas
	Guangzhou Petrochemical	GMR（Duplex)	Flare gas control	Oil & Gas
	Guangzhou Petrochemical	GMR（Duplex)	Distilatory vessel ESD	Oil & Gas
	CNOOC Nanbao 352-CEP Platform	GMR（Duplex）  2 sets, one is ESD, the other is FGS	ESD and F & Gas	Oil & Gas
	CNOOC Nanbao 352-B platform	GMR（Duplex）  2 sets, one is ESD, the other is FGS	ESD and F & Gas	Oil & Gas
	Shandong Yanzhou Mining Bureau Cathay coal gasification plant	GMR（Triplex）	Coal gasifier for 200K tons ethylic acid ESD	Coal Chemical
	Shenhua Ningxia coal industry group methanol plant	GMR（Duplex）	The methanol synthesis gasTurbine control	Coal Chemical
	Shandong Yanzhou Mining Bureau Cathay coal gasification plant	GMR（Triplex）	Coal gasifier for 200K tons ethylic acid ESD	Coal Chemical
	Changqing refinery oil plant	GMR（Triplex）	Heavy oil hydrogenation ESD	Petro-Chemical
	Changqing refinery oil plant	GMR（Triplex）	Heavy oil hydrogenation ESD	Petro-Chemical
	Changqing refinery oil plant	GMR（Triplex）	centrifugal blower control	Petro-Chemical
	Sinopec Hubei Chemical Fertilizer Branch	GMR（Triplex）	Ammonia & Urea ESD	Chemical fertilizer
	Wuhan Petrochemical Co., Ltd.	GMR（Triplex）	Refinery ESD	Petro-Chemical
	Weinan chemical fertilizer plant	GMR（Triplex）	Methanol/dimethyl ether ESD	Chemical

Outside China:

Country	Enduser	Product	Application	Location
TX	Texaco/Huntsman		Substation	Port Neches
TX	Texaco/Huntsman		Epoxidation reactor	Port Neches
TX	Texaco/Huntsman		Epoxidation reactor	Port Neches
TX	Texaco/Huntsman		BMS	Port Neches
TX	Texaco/Huntsman		Ground Flare	Port Neches
TX	Texaco/Huntsman		Vapor recovery	Port Neches
TX	Texaco/Huntsman		MTBE SIS	Port Neches
TX	Solvay Polymers		SIS	Houston
TX	Texaco/Huntsman		Exothermic reactor	Port Neches
TX	Elf Atochem		BMS	Port Neches
TX	Texaco/Huntsman		BMS	Port Neches
TX	Diamond Offshore		FPSO	Houston
UK	Maersk #1		Offshore platform	N.Sea
UK	ARCO British		Trent & Tyne Platforms	North Sea
UK	Rasmussen		FPSO	Far East
UK	Schaffer/Clipper		Subsurface BOP	US Gulf
UK	Rolls Royce		CHP-DCS	UK
UK	BP Scheihallion		FPSO - DCS	UK
UK	Rolls Royce		CHP-DCS	UK
UK	Kerr Mcgee		Janice Platform	North Sea
UK	Rolls Royce		Turbine Control	UK
USA	Columbia Gulf		Gas turbine	Houston
	Texaco / Huntsman		F6 Boiler Project	Port Neches
	TPI/ Rayong		Fire & Gas System	Chicago
	Noble Drilling EVA1		EVA 4000-2 DS/BOP	Houston
	Noble Drilling EVA2		EVA 4000-2 DS/BOP	Houston
	Pemex/Modec		EVA 4000-2 DS/BOP	Houston
	Noble - Amos Runner		Deepwater BOP	US Gulf
	Noble - Paul Romano		Deepwater BOP	US Gulf
	Noble - Paul Romano		Ballast Control System	US Gulf
	Noble - Amos Runner		Ballast Control System	US Gulf
	R&B		Deepwater BOP	US Gulf
	Conoco		Deepwater BOP	US Gulf
	Falcon		Deepwater BOP	US Gulf
	Diamond Offshore		Deepwater BOP	US Gulf
USA	Varco-Shafer		Deepwater BOP	US Gulf
	Elliott		Turbo machinery Cntl	PA
	POMA OTIS		People Mover System	Detroit
	Minneapolis Airport		People Mover	Minneapolis
Australia	Woodside Petroleum		Fire & Gas and ESD	Australia
	Cabbott		BMS	Melborne
	Orica		Ethlyene Liquifaction	NSW
Canada	Shell Canada		Hydrocracker ESD	Sarnia, Ontario
	Shell Canada		#1 Crude Heater SIS	Sarnia, Ontario
	Shell Canada		Sulfur Plant	Sarnia, Ontario
	Shell Canada		火力加热器	Montreal
	Toronto Transit		15地铁动力控制站	Toronto
QATAR	QGPC		SIS	Halul Island
	Occidental Petroleum		Turbine control	Middle East Gulf
Mexico	Pemex		Fire & Gas	Atcapozalco
	Pemex		FCCU	Monterey
	Pemex - Caderayta		Fire & Gas	Monterey
	Pemex		Gasoline Term	Reynosa
	Pemex - Caderayta		FCCU SIS	Monterrey
	Pemex - Caderayta		Crude Unit F&G	Monterrey
	Pemex		Fire & Gas	Monterrey
	Pemex		Coker - ESD	Monterrey
Portugal	PROET		6-BMS - Phase 2	Sines
	PROET		6-BMS - Phase3	Sines
India	Numagahali		All Processes	Numagahali
	Indian Oil Company		Chem Plant SIS	India
	Engineers India Ltd		Petrochemical Complex	Numaligarh Refinery
	Numaligarh Refineries Ltd		ESD system for complete refinery	Numaligarh （ASSAM）
	Numaligarh Refineries Ltd.		Refinery Emergency Shutdown	Assam
	NFL Vijaypur		Burner Management System	Vijaypur
	NTPC-Talcher R&M		62.5 MW Thermal Power Station, Furnace Safety Supervisory System (FSSS) and Soot Blower Control System.	Talcher
	IOCl - Kandla		Fire Water Pump Control System	Kandla
	Cochin Refinery		4 BMS系统	Assam

 

13.2    PAC8000

 

Country	Enduser	Product	Application	Date
China	CNPC Jilin petrochemical		Tank farm
	Wuxi Dongtai fine chemical industry		Total Plant Control
	Yixing Mingyang chemical		Total Plant Control
	Leshan Yongxiang resins Co.,LTD		VCM
	Shanxi Antai Group Co., Ltd		Coal Coking
	QilSinopec Qilu Petrochemical Corporation Group.		Boiler
	CNPC the southwest pipeline		Tank farm
	Hainan refinery plant		Port and alkali waste control
	Yingkou Jia Fu petrochemical		Total Plant Control
	Sinpopec Yanshan petro chemical		Boiler
	INNER MONGOLIA YILI ENERGY COMPANY LIMITED YiLi Chemical branch		Acetylene Silo control
			VCM
			PVC
			solid caustic soda evaporation
			Centrifugal drying
			Waste water processing
			Compressed air and nitrogen
	Jidong Oilfield		Oil pretreatment
	Harbin-Dalian pipeline		Pump Station、Tank farm
	ShanXi HongKong China Co.,LTD		Coal gasification
	Taicang reserves of oil depot		Tank Farm、Port
	Hefei emergency peak-shaving gas engineering		LNG
	CNOOC Weizhou Island offshore platform		Offshore Platform
	Lan_Zheng-Chang Pipeline		Station、Tank farm
	Liuzhou Chemical Industry Co., Ltd urea synthesis tower		Urea
China	Tianjin Shun Da LNG		LNG
	The second Shaanxi-Beijing Pipeline		Gas Pipeline
	Zhongyuan Oilfield		Refinery
	Zhongyuan Oilfield refinery Plant		Torch Control
	Zhejiang Yinzhou lubricating oil		Petro-Chemical
	JINZHOU PETROCHEMICAL CO.,LTD refinery plant		Tank farm
	CNPC Southwest oil and gas field Guang An		Vapor recovery system
	ZHE JIANG XINAN CHEMICAL INDUSTRIAL GROUP CO ,LTD		Chemical
	Sichuan Nature Gas metering station		Nature Gas
	Inner Mongolia LNG		LNG
	SiChuan Norh-West Gas Field		Gas Field
	DongFang Xin Xiwang Chemical		Chemical
	The second Shaanxi-Beijing Pipeline Baozhou Gas ststion		Gas Pipeline
	Sinochem Lai Chang Pipeline		Chemical pipeline
	The Sudan gas pipeline		Gas field
	The Central Asian HuiYin pipeline		Oil Pipeline
	Dunhua wood		Chemical
	Mo Da Pipeline		Gas Pipeline
	Hengxiang Polypropylene unit		Polypropylene unit
	SiChuan North-West Gas field		Gas Pipeline
	Qinghai Kunlun Gas LNG		LNG
	CNPC Sichuan Qionglai		Gas Pipeline
	Xinjiang Hetian LNG		LNG
	Tibet LNG		LNG
	CNPC South-West O & G Gas field		Gas Pipeline
	Chongqing Songzao coal mining		Coal Chemical

 

14    Appendix 2: Successful Project Information

15    Appendix 3: GEIP Product Datasheet and Certification

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