MGP1 Boc1888po001 C19 0001 - 003

Majnoon Oil Field EPCM Services Project
COMMENTS RESPONSE SHEET (CRS)

FUNCTIONAL DESIGN SPECIFICATION
Document Title : (CONTROL SYSTEM DESCRIPTION) - CPF1 Company Job No. :
GAS METERING SKID
Discipline : Contractor Job No. : 33013M
Document No. : MGP1-BOC1888PO001-C19-0001
Status
Serial No. Page No. / Section Rev. Company Comment Contractor Response Resolution
(Open /Close)
1 Page No. 24 002 Noted & Incorporated
GC-434 Diagnostics link is connected to Ethernet Switch-1 & GC-454 Diagnostics

2 Page No 26 002
link is connected to Ethernet Switch-2, System architecture snap is updated in FDS.
Terminal Server is having only single ethernet port connected to Single Ethernet
3 Page No 27 002 Switch. As this only related to Daignostic purpose, not required to be connected on
both Network.
Page No 30 002 Noted & Updated the Tag Numbers
Page 1 of 4
GAS METERING SKID
Status
(Open /Close)
Yes, these two signals are hardwired between FC & PLC, these signals will be
4 Page No 30 002
indicated on latest revision of system architecture
5 Page No 31 002 Noted & Incorporated
6 Page No 35 002 Noted, RGC 3000 will be provided on both MSC.
As this project is having SICK usm flow meter, The VCF calculation equation has
7 Page No 55 002 been updated in the FDS rev 002 and unnecessory equation (which does not relate to
sick usm VCF calculations) has been deleted from the document.
GC Diagnaustic link is only to be used from its diagnaostic software. Link fail alarm
8 Page no 70 002
is added to scada system. This alarm is indicated in Alarm List of FDS.
Page 2 of 4
GAS METERING SKID
Status
(Open /Close)
9 Page no 71 002 Noted & Incorporated
10 Page no 71 002 Noted, Tag number are added to PLC I/O assignment section tables
12 Page no 81 002 Noted & Incorporated(Internal Signals there are no tags)
Noted, actual tags will be indicated in actual MSC Alarm with Tag number &
13 Page no 91 002 Location, this is generalized Alarm types and categories of alarm that will be
generated shown in Alarm Section of FDS.
Noted, Revised system architecture document will be submitted for review &
15 Page no 111 002
approval
AGA 8 Calculation reference updated as per Project Uncertainity Document (MGP1- AGA 8 Calculation reference updated to AGA 8 Part 2 GERG 2008 calculation
16 Page no. 58 002
BOC1888PO001-F51-0003) section 4.2 Density calculation requirement. standard
Page 3 of 4
GAS METERING SKID
Status
(Open /Close)
CONTRACTOR COMPANY
Prepared By: Piyush Parmar

Date: Approved By: Date:
Signature:
Approved By: Amit Chauhan

Date: Signature: Date:
Signature:
Page 4 of 4
METERING SKID FOR MAJNOON OIL
FIELD DEVELOPMENT PROJECT
VENDOR DOCUMENT REVIEW SHEET
Purchase Order Number: BOC-PO-1888-001
Purchase Order Title: BOC-1888- GAS METERING SKID FOR CPF1
Suppliers Name: ALDERLEY
Suppliers Reference Number and Revision: No. Rev.

33013M-01-C-0940-01 003
Supplier (Prepared By) Rashmikant Prajapati
Supplier (Checked By) Amit Chauhan
Supplier (Approved By) with Date Renji Mathew

23-May-2024
Document Description:
FUNCTIONAL DESIGN SPECIFICATION (CONTROL SYSTEM DESCRIPTION) - CPF1 GAS METERING
SKID
Equipment / Tag Number(s):
CP000-51-A-005 for Metering Skid
Project № PO.№ VDRL Code Seq. № Sheet No. Rev. No. Status code
MGP1 BOC1888PO001 C19 0001 001 003 IFA

Also Covers
SDRL codes C19
COMPANY review and comments shall not be assumed to indicate either responsibility or liability for accuracy and
completeness of this document or to alter any contractual terms and conditions.
Review Code and Status
Code 1 Accepted – Up-rev and Resubmit with applicable document lifecycle status code
Revise and Resubmit –Incorporate Comments, Up-Rev & Resubmit at the next document
Code 2 lifecycle status code – Work May Proceed
Rejected– Address highlighted deficiencies, Up-Rev and Resubmit at the next document lifecycle
Code 3 status code – Work May not proceed
Code 4 Review Not Required – Do not resubmit
Code 5 Cancelled
Code 6 Information
Date: Sign:
Note: This sheet shall be the 1st cover page of all A3 & A4 documents. This block will also form part of the
A3 drawing template.
CLIENT: BASRA OIL COMPANY (BOC) / KBR.
PROJECT: Majnoon Oil Field EPCM Services

Project
Alderley FZCO
SUBJECT: CUSTODY TRANSFER METERING SKID - SOUR
& SWEET GAS
Functional Design
CLIENT REFERENCE: BOC-PO-1888-001
Specification
DOCUMENT NO. : MGP1-BOC1888PO001-C19-0001
DATE: 21/05/2024
(Revision 003)
FDS STAGE: STAGE 03
Document Number: MGP1-BOC1888PO001-C19-0001 Alderley Document Number: 33013M-01-C-0940-01

Document Name: Functional Design Specification
Rev 003 Page 1 of 115
❖ Disclaimer
No part of this document may be used, translated into another language, stored in a retrieval system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or
otherwise, without prior written consent.
While every effort has been made to ensure the accuracy of this document, Alderley assume no
responsibility for the consequences of any omissions or errors, neither is any liability assumed for
damages resulting from the use of information contained herein.
Alderley FZCO reserves the right to revise any information contained in this document without prior
notice.
❖ Safety Considerations
Whilst Alderley has designed its products using industry standards to always operate safely, they
should not be considered as a safeguarding element in a system. It is anticipated that any safety critical
function should pass through a separate safety critical control system.
❖ Revision History
Rev Date Purpose of Revision Prepared Checked Approved
001 27-Sep-2023 First issue for client review RP AC AC
002 06-Feb-2024 Clients Comment Incorporated PP AC AC
003 22-May-2024 Clients Comment Incorporated PP AC AC
❖ Hold History
Date Approval Hold
No Date Ended Purpose of Hold
Started for Hold Resolved
❖ Section Hold
Section
Section Description
Hold No
1
2
3
4

❖ SECTIONS
1 SCOPE OF DOCUMENT
2 PROJECT CESCRIPTION
3 METERING SKID OVERVIEW
4 METERING CONTROL SYSTEM
5 METERING CONTROL PANEL
6 METERING SYSTEM BILL OF MATERIAL
7 FLOW COMPUTER
8 GAS CHROMATOGRAPH
9 PROGRAMMAGBLE LOGIC CONTROLLER (PLC)
10 METERING SUPERVISORY COMPUTER (PLC)
11 FIRE ALARM CONTROL PANEL (FACP)
❖ ANNEXURES
A YEARLY REPORT FORMAT
B DAILY QUALITY REPORT FORMAT
C DAILY QUNTITY REPORT FORMAT

CONTENTS
❖ Disclaimer........................................................................................................................................ 2
❖ Safety Considerations ..................................................................................................................... 2
❖ Revision History .............................................................................................................................. 2
❖ Hold History .................................................................................................................................... 2
❖ Section Hold .................................................................................................................................... 2
❖ SECTIONS......................................................................................................................................... 3
❖ ANNEXURES..................................................................................................................................... 3
1. Scope of Document ....................................................................................................................... 10
1.1. Explanation of Alderley’s Multi-Stage Functional Design Specification ........................................ 10
1.1.1. Stage 1 – Fundamental Principles and Operation............................................................... 10
1.1.2. Stage 2 – Detailed Design ................................................................................................... 10
1.1.3. Stage 3 – Final Details ......................................................................................................... 10
1.1.4. Stage 4 – As Built/Tested .................................................................................................... 11
1.1.5. Hold ..................................................................................................................................... 11
1.2. Description of Section Test Procedure .......................................................................................... 11
1.2.1. How will the Functionality Testing Box be used? ............................................................... 11
1.3. Test Procedure ............................................................................................................................... 13
1.3.1. Schedule .............................................................................................................................. 13
1.3.2. Metering Control Panel Test Sequence .............................................................................. 13
1.3.3. Completion of Acceptance Test Manual (ATM) .................................................................. 14
1.3.4. Completion of Factory Acceptance Test (FAT) .................................................................... 14
1.3.5. System Query Reports ........................................................................................................ 14
1.4. Abbreviations ................................................................................................................................. 15
2. Project Description........................................................................................................................ 17
2.1. Operating Conditions ..................................................................................................................... 17
2.1.1. Gas Operating Conditions ....................................................................................................... 17
2.1.2. Gas Composition ..................................................................................................................... 18
2.1.3. Environmental Conditions ...................................................................................................... 18
2.1.4. Electrical Supplies ................................................................................................................... 18
2.2. Measurement Units ....................................................................................................................... 19
2.3. Total Rollover ................................................................................................................................. 20
2.4. Reference Documentation ............................................................................................................. 20
2.5. Reference Specifications ................................................................................................................ 21
2.6. Metering Standards ....................................................................................................................... 22
2.7. Calculation Accuracy ...................................................................................................................... 22
2.8. Uncertainty Calculations ................................................................................................................ 22
3. Metering Skid Overview ................................................................................................................ 23
3.1. Meter Run Components................................................................................................................. 23
3.2. 2 x 100% Metering System............................................................................................................. 23
3.3. Motor Operated Valve (MOV) ....................................................................................................... 23
3.4. Flow Meter ..................................................................................................................................... 24
3.5. Gas Chromatographs ..................................................................................................................... 25
4. Metering Control System .............................................................................................................. 26
4.1. Metering Control System Functions .............................................................................................. 27
4.2. Flow Computer Functions .............................................................................................................. 28
4.3. PLC Function (CP000-5100-PLC-401 & CP000-5100-PLC-402) ....................................................... 30
4.4. MSC Function ................................................................................................................................. 31
4.5. Ethernet Communication Network Details .................................................................................... 32
5. Metering Panel.............................................................................................................................. 33
6. Metering System Bill of Material .................................................................................................. 34
6.1. Metering Control Panel Hardware ................................................................................................. 34
6.2. Loose Supply Hardware ................................................................................................................. 34
6.3. Software Licences & Media............................................................................................................ 35
7. Flow Computer.............................................................................................................................. 36
7.1. Introduction ................................................................................................................................... 36
7.2. Flow Computer details ................................................................................................................... 37
7.3. Displays .......................................................................................................................................... 37
7.4. Local LCD Display ........................................................................................................................... 38
7.5. Keypad............................................................................................................................................ 38
7.5.1. Function Keys ...................................................................................................................... 38
7.5.2. Direction Key ....................................................................................................................... 38
7.5.3. Menu Key ............................................................................................................................ 38
7.5.4. Numeric Keys ...................................................................................................................... 38
7.5.5. Operating Keys .................................................................................................................... 38
7.5.6. Alarm Keys .......................................................................................................................... 39
7.6. Web Interface ................................................................................................................................ 39
7.7. Changing Data ................................................................................................................................ 39
7.8. Alarms ............................................................................................................................................ 39
7.9. Flow Computer Access Levels ........................................................................................................ 40
7.10. Flow Computer Operation ........................................................................................................... 40
7.10.1. Calculation Method........................................................................................................... 40
7.10.2. Stream Status .................................................................................................................... 40
7.10.3. Maintenance Mode........................................................................................................... 41
7.10.4. Totalisation ....................................................................................................................... 42
7.10.5. Base Time .......................................................................................................................... 43
7.10.6. Totals Reset ....................................................................................................................... 43
7.10.7. Duty / Standby Redundancy ............................................................................................. 44
7.10.8. Check Metering ................................................................................................................. 45
7.10.9. S600+ Check Metering Flow Chart .................................................................................... 46
7.10.10. Alarm Transmitted to MSC.............................................................................................. 47
7.10.11. Flow Computer Communications ................................................................................... 47
7.11. Metering Run Instruments ........................................................................................................... 48
7.12. Pulse Inputs Signals ...................................................................................................................... 48
7.12.1 USM Transmitter ................................................................................................................ 48
7.13. Analog Inputs Signals ................................................................................................................... 48
7.13.1. Stream Pressure Transmitter ............................................................................................ 48
7.13.2. Stream Temperature Transmitter ..................................................................................... 49
7.14. Digital Inputs Signals .................................................................................................................... 49
7.14.1. USM Fault Signal ............................................................................................................... 49
7.15. Signals Interfaced with Flow computers other than Meter runs................................................. 50
7.15.1. Duty / Standby Signal ........................................................................................................ 50
7.16. S600+ Connection Schedule for Flow Computers........................................................................ 51
7.16.1. P152 CPU: FC-A & FC-B ..................................................................................................... 51

7.16.2. P144 I/O: FC-A & FC-B ....................................................................................................... 52
7.17. Calculations .................................................................................................................................. 53
7.17.1. Flowrate Calculation ......................................................................................................... 53
7.17.2. Total Calculation ............................................................................................................... 56
7.17.3. Density Calculations .......................................................................................................... 58
7.17.4. AGA 10 Calculations .......................................................................................................... 60
7.17.5. ISO6976 Calculations ........................................................................................................ 60
7.17.6. Flow Weighted Averages (Stream Level) .......................................................................... 62
7.17.7. Flow Weighted Averages (Station) ................................................................................... 63
7.17.8. Component Averaging ...................................................................................................... 63
7.17.9. Linearization Curve Calculation ........................................................................................ 64
7.17.10. Unit Conversion Factors (Metric to Imperial Units) ........................................................ 64
8. Gas Chromatograph ...................................................................................................................... 66
8.1. Introduction ................................................................................................................................... 66
8.2. Basic Function ................................................................................................................................ 66
8.3. Communication To Gas Chromatograph ....................................................................................... 66
8.4. GC Operating Mode ....................................................................................................................... 67
8.5. GC Analysis Data Handling ............................................................................................................. 68
8.6. Chromatograph Alarms .................................................................................................................. 70
9. Programmable Logic Controller .................................................................................................... 71
9.1. Introduction ................................................................................................................................... 71
9.2. PLC Digital Input Signals ................................................................................................................. 71
9.2.1. MOV Status ......................................................................................................................... 71
9.2.2. Panel Over Temperature ..................................................................................................... 72
9.2.3. PSU 24V DC Fail ................................................................................................................... 72
9.2.4. UPS 240V AC Fail ................................................................................................................. 72
9.2.5. FAN Fail ............................................................................................................................... 72
9.2.6. GC-A Sample Flow Low ....................................................................................................... 72
9.2.7. GC-B Sample Flow Low........................................................................................................ 72
9.2.8. Level-1 ESD signal from ICSS ............................................................................................... 73
9.2.9. Level-2 ESD signal from ICSS ............................................................................................... 73

9.2.10. Level-1 PSD signal from ICSS ............................................................................................. 73
9.3. PLC Digital Output Signals .............................................................................................................. 74
9.3.1. MOV Commands ................................................................................................................. 74
9.3.2. Clear to Check ..................................................................................................................... 74
9.3.3. Check Meter Inlet MOV Close Status .................................................................................. 74
9.4. PLC Analog Input Signals ................................................................................................................ 75
9.4.1. GC- Carrier & Calibration Gas Cylinder Pressure ................................................................ 75
9.4.2. Moisture Analyser ............................................................................................................... 75
9.4.3. Stream Differential Pressure ............................................................................................... 75
9.5. Communication To MSC................................................................................................................. 76
9.6. Operation & Control ...................................................................................................................... 76
9.6.1. MOV Interlocks ................................................................................................................... 77
9.6.2. Stream Commands .............................................................................................................. 78
9.6.3. Stream Open Control .......................................................................................................... 78
9.6.4. Stream Close Control .......................................................................................................... 78
9.6.5. Stream Align Control ........................................................................................................... 78
9.6.6. Stream De-Align Control ..................................................................................................... 78
9.6.7. Stream Status ...................................................................................................................... 79
9.6.8. Change Stream on Failure ................................................................................................... 79
9.7. PLC Connection Schedule............................................................................................................... 80
9.7.1. PLC System Card Layout ...................................................................................................... 80
9.7.2. PLC I/O Assignment ............................................................................................................. 81
10. Metering Supervisory Computer (MSC) ........................................................................................ 89
10.1. Introduction ................................................................................................................................. 89
10.2. MSC Function ............................................................................................................................... 89
10.3. MSC Summary .............................................................................................................................. 89
10.3.1. MSC Security ..................................................................................................................... 90
10.3.2. MSC Virus Protection ........................................................................................................ 90
10.3.3. MSC Report Archiving ....................................................................................................... 90
10.3.4. Metering Supervisory Computer, Software Summary...................................................... 91
10.4. MSC Alarms .................................................................................................................................. 91

10.4.1. Process Alarms .................................................................................................................. 92
10.4.2. System Alarms................................................................................................................... 94
10.4.3. Computer Alarms .............................................................................................................. 95
10.5. MSC Reports................................................................................................................................. 96
10.5.1. Report Archiving ............................................................................................................... 96
10.5.2. Report Descriptions .......................................................................................................... 97
10.5.3. Current Status Report ....................................................................................................... 98
10.5.4. Hourly Report .................................................................................................................... 99
10.5.5. Daily Report..................................................................................................................... 100
10.5.6. Monthly Report ............................................................................................................... 101
10.5.7. Yearly Report................................................................................................................... 102
10.5.8. Check Comparison Report .............................................................................................. 102
10.5.9. Maintenance Report ....................................................................................................... 103
10.5.10. Parameter Report ......................................................................................................... 104
10.5.11. Chromat Analysis Report .............................................................................................. 104
10.5.12. Active Alarms Report .................................................................................................... 105
10.5.13. Daily Alarms Report ...................................................................................................... 105
10.5.14. Daily Events Report ....................................................................................................... 106
10.5.15. Daily Quality Report ...................................................................................................... 106
10.5.16. Daily Quality Report ...................................................................................................... 106
10.6. Communication To ICSS ............................................................................................................. 107
11. Fire Alarm Control Panel (FACP) ................................................................................................. 108
11.1. Fire & Gas Detectors .................................................................................................................. 108
11.2. Fire & Gas PLC ............................................................................................................................ 109
11.3. FACP Communication to DCS / ICSS ........................................................................................... 112
11.4. UPS System Design and calculations.......................................................................................... 112

1. Scope of Document
1.1. Explanation of Alderley’s Multi-Stage Functional Design
Specification
This document is a Stage 3 Functional Design Specification. The reason for splitting up our Functional Design
Specification into multiple stages is to encourage correctness of this document first time, by avoiding
assumptions being made because of not having all necessary information. This method aims to update Basra Oil
3
3 Company (BOC) / KBR on the functional details of the project at a quicker rate than was possible without this
method. Due to the nature of this engineering document, all the information required to complete all four stages
of the Functional Design Specification will not be known at the 1st stage. As a result, each stage aims to build
upon the last, progressing to a finalised completed document.
The following will detail what each stage will compose of:
1.1.1. Stage 1 – Fundamental Principles and Operation

The very first stage of Alderley’s Multi-Stage Functional Design Specification document is aimed to give a general
overview of the system that as well as to detail the fundamental principles of the scope of supply. Within the 1st
stage of this document, the system equipment to be supplied for use within the control system and the
Mechanical skid will be described.
Further to this we will provide details of the operations that the system will perform, explaining why we are
performing them and how they work. Details of the system hardware and software to be provided will be given.
Finally, we will list the standards to be used, project specifications that we have received and measurement units
to be used.
1.1.2. Stage 2 – Detailed Design

The second stage will add comprehensive detail adding to the fundamental principles presented in the stage 1.
Within this stage the system Inputs and system Outputs will be given for analogue, digital, serial, frequency, and
pulse types of I/O. Further to this the process behind the calculations have used for Gas Metering (Fiscal) Package
will be explained with the assistance of flowcharts.
The various operational aspects of the system will be explained, giving summary of the alarm types that are
possible to be displayed on the Metering Supervisory Computer. The report categories that are available from
the Metering Supervisory Computer will also be stated. From this stage onwards, screen shots from the Human
Machine Interface (HMI) will be added to provide visualisation of screens and functions that would be
encountered during operation.
1.1.3. Stage 3 – Final Details

In the third stage, details will be finalised regarding the last aspects of the design. This will include the addition
of flow computer I/O lists. Second to this, the process behind operations carried out by the system will be greater
explained with the addition of flow charts. Finally, Software Development System information will be added.

1.1.4. Stage 4 – As Built/Tested
The final stage of our Functional Design Specification for Basra Oil Company (BOC) / KBR. will include as built
printouts for the project and will include hardware and software records.
1.1.5. Hold
Information that is required to complete a section within one stage of the Functional Design Specification has
not been detailed. If this was to occur, then a hold can be put on the current stage of the document. This would
prevent completion of that stage/hence the next stage is prohibited from starting. A hold can be removed by
Alderley if the information that was required has been received.
1.2. Description of Section Test Procedure

The following is a box used to verify the functionality for the equipment being supplied. To do this the following
has been placed at the end of the section that needs checking within this document. In due course our
Acceptance Test Manual (ATM) for the computer system will be submitted. The testing box will remain empty
until completion of the Acceptance Test Manual (ATM).
Feature Tested
Functionality Tested Evidence: Section XX

(Check Box) [Doc No: 33013M-01-C-0941-01 – Rev X]
Signed: Date: Alderley:
Basra Oil Company (BOC) /

Approved: Date:
KBR.:
Comments:
The purpose of its inclusion is that it strives to ensure that FDS sections that we are providing you will be
thoroughly tested, and this will be indicated by a full section that has been signed by both Alderley Engineers
and then witnessed by Basra Oil Company (BOC) / KBR.. Evidence of the section can be located with reference
to the test procedure performed as part of the Acceptance Test Manual and evidence compiled by Alderley.
1.2.1. How will the Functionality Testing Box be used?

The following will demonstrate the process involved with this procedure and how this will appear within your
project:
1. Our Acceptance Test Manual is progressively completed by an Alderley Engineer during system testing.
Once a test has been completed and evidence is provided as proof, it is signed and dated. For this
example, in the Acceptance Test Manual Example has been completed.
2. Following this the Alderley Engineer can now confirm (by giving evidence from the Acceptance Test
Manual) that item X.XX (where x is numeric digit); within the Functional Design Specification Example,
has been successfully tested for its functionality and that it operates as stated in the Functional Design
Specification. The Alderley Engineer would then sign the Functionality Testing Box confirming this and
thus referring to the test performed in the Acceptance Test Manual.

3. During the Factory Acceptance Test which is witnessed by Basra Oil Company (BOC) / KBR., every item
within the Functional Design Specification will be signed off individually for the package, by referring to
the evidence provided in the Functionality Testing Box.
4. Once all Functionality Testing Boxes have been fully witnessed by Basra Oil Company (BOC) / KBR., then
the package is fully functional and system testing is complete.
Acceptance Test Manual
1
.
3
.
Functional
Design
Specification
2
.
(FDS)

1.3. Test Procedure
1.3.1. Schedule
Alderley Internal Testing of this system comprises of two phases:
1. Verification of Metering Control Panel Functionality

2. Verification of Metering Skid functionality and operation by Metering control
The diagram below illustrates the process:
1.3.2. Metering Control Panel Test Sequence

By the end of this sequence the operation and functionality of the Metering Control Panel would be verified.
Alderley perform internal testing of the Metering Control Panel by following testing procedures set out in
Acceptance Test Manual (ATM). Upon completion of the ATM, a Factory Acceptance Test will take place for
Basra Oil Company (BOC) / KBR. to witness the operation and functionality of the Metering Control Panel. The
diagram below illustrates the process:
Metering Control Panel

Test Sequence
Completion of
Completion of
Factory
Acceptance Test
Acceptance Test
Manual (ATM)
(FAT)
Verification of Simulated Metering Skid

Operation by Metering Control Panel in
Compliance with Functional Design
Specification (FDS)

1.3.3. Completion of Acceptance Test Manual (ATM)
Before this stage can be started, Client approval of the Acceptance Test Manual (ATM) and the Functional Design
Specification (FDS) documents are required.
The Acceptance Test Manual (ATM) Procedure sets out tests that must be completed by Alderley, designed to
provide a level of confidence in the Metering Control Panel.
To complete the ATM for the Metering Control Panel, simulation must be used and hence will take the role of a
Metering Skid. This means that the functionality of the Metering Control Panel can be tested. This method will
give confidence that the Metering Control Panel is functional as well as detailing what will be expected when (if)
the Metering Control Panel is connected to a Metering Skid.
The completion of the Acceptance Test Manual (ATM) is undertaken in conjunction with the simulation of
control signals to the Control Panel.
1.3.4. Completion of Factory Acceptance Test (FAT)

A Client Witnessed FAT for the Control Panel is where the client witnesses the Internal Simulation Testing
performed by Alderley and verifies that it complies with the procedures set out in the Acceptance Test Manual
(ATM). Further to this, the Client will verify that each item within the Control Panel operates as described within
the Functional Design Specification (FDS) and will acknowledge this by signing off each Functionality Test Box.
During the FAT, the FAT document will be completed. This document will be used to record the tests that have
been carried out within the Client Witness Factory Acceptance Test and to record Client verification of Metering
Control Panel functionality.
Refer to Alderley Document Number: 33013M-01-C-0941-01(Client Doc no MGP1-BOC1888PO001-H08-0002)
for tests covered.
1.3.5. System Query Reports

If a fault is found during any stage of testing, then the details are recorded on a System Query Report (SQR)
form. Continuation of testing depends on the nature of the fault. Any SQRs raised will be recorded and must be
signed off individually when resolved to allow for completion of System Testing. For an SQR to be cleared,
evidence of retesting of the query must be appended to the original testing fault.

1.4. Abbreviations
Abbreviation Meaning
AC Alternating Current
ADC Analogue to Digital Converter
AGA American Gas Association
API American Petroleum Institute
ASCII American Standard Code of Information Interchange
AMS Asset Management System
ATM Acceptance Test Manual
AVG Average
CCR Central Control Room
CMW Central Maintenance Workstation
COM Communication Port
CPL Pressure Correction Factor
CPU Central Processing Unit
DAC Digital to Analogue Converter
DC Direct Current
DCS Distributed Control System
DRAM Dynamic Random-Access Memory (Not Battery Supported)
EEPROM Electrically Erasable Programmable Read Only Memory
FAT Factory Acceptance Test
FC Flow Computer
FCV Flow Control Valve
FDS Functional Design Specification
FR Flowrate
GPA Gas Processors Association
H/W Hardware
HART Highway Addressable Remote Transducer
HMI Human Machine Interface
I/O Input/Output
I/P Current to Pneumatic
IC Integrated Circuit
IE Instrument Earth
IP Ingress Protection
IP Address Internet Protocol Address
IR Infra-Red
IS Intrinsically Safe
ISO International Standards Organisation
LAN Local Area Network
LCP Local Control Panel
LCR Local Control Room
LER Local Equipment Room
LT Long Tonnes
mA Milli-Ampere
MCP Manual Alarm Call Points
MCC Motor/Mains Control Centre
MCR Metering Control Room
MMI Man Machine Interface

Abbreviation Meaning
MOV Motor Operated Valve
MPMS Manual of Petroleum Measurement Standards
MSC Metering Supervisory Computer
MTBF Mean Time Between Failures
NACE National Association of Corrosion Engineers
NB Nominal Bore
NGL Natural Gas Liquid
NPT National Pipe Thread
O&M Operation and Maintenance Manual
OOL Out of Limits
OWS Operator Workstation
P&ID Piping & Instrumentation Diagram
PC IBM Compatible Personal Computer
PE Protective Earth
PLC Programmable Logic Controller
PSU Power Supply Unit
RAL Reichsausschuss fur Lieferbedingungen (Paint Colour)
RAM Random Access Memory
RTC Real Time Clock
RTU Remote Telemetry Unit
RX Received Information
S/W Software
SAT Site Acceptance Test
SRAM Static Random-Access Memory (Usually Battery Supported)
SVOL Standard Volume
S600+ Emerson FloBoss S600+ Flow Computer
TCP/IP Transmission Control Protocol/Internet Protocol
TX Transmitted Information
UCP Unit Control Panel
UPS Un-interruptible Power Supply
USB Universal Serial Bus
V Volts
Vac Volts, Alternating Current
VCF Volume (Temperature) Correction Factor
Vdc Volts, Direct Current
VDU Visual Display Unit
W Watts (Power, Including Power Factor)

2. Project Description
The Majnoon Oil Field is in the south of the Mesopotamian Basin of South Iraq and about 50 km north of Basra.
The field was discovered in 1976 and the Iraq Ministry of Oil estimate in-place volumes at approximately 38
billion barrels of oil.
The field consists of 5 major and 8 minor stacked reservoirs. Currently four of the major reservoirs, Mishrif,
Hartha, Nahr Umr and Zubair are being developed.
Majnoon operations commenced in 2012 with 18 wells and a new central processing facility CPF-1 near the
existing Degassing Station (DS-2). Current production from Majnoon is about 220 KBOPD.
The targeted reservoir for the Majnoon Growth Project (MGP) is the Mishrif sour formation. This is the largest
among the Majnoon reservoirs and holds about 50% of the total field in-place volumes.
CPF-1 station, with a nameplate capacity of 100 KBOPD, DS-2 station, with a nameplate capacity of 120 KBOPD,
both receive feed from sweet and sour reservoirs. As of early 2019, both facilities are running in dry mode and
exporting sweet gas & processed oil. Sour gas is being flared.
New Custody Transfer Metering 2 X100 % with Check metering system for Sweet Gas is supplied as part of this
package.
The purpose of this Detailed Functional Design Specification is to define the functionality of the metering system
at new central processing facility, Majnoon Oil Field.
The metering system is provided in 3-Bay metering control panel with overall dimension of Height: 2100mm
(including 100mm plinth) X Width: 2400mm X Depth: 800mm. This metering control panel is provided with
redundant flow computers, redundant Metering Supervisory Computers (MSCs) with individual panel mount
monitor and keyboard, redundant Programmable Logic Controllers (PLC) with redundant I/O system, redundant
24V DC power supplies, redundant network switches and other accessories as required.
This document is issued for customer approval before production and software implementation commence.
2.1. Operating Conditions

Operating conditions in below table are updated below (as per client document no.PPP-GEN-KBR-IN-7739-0001).
2.1.1. Gas Operating Conditions

Product Sweet Gas
Operating @MINIMUM @NORMAL @MAXIMUM Units
Cases/Description
Flow Flow Flow
Station Flowrate 2.8 90 140 MMSCFD
Operating Pressure 52.5 52 52 barg
Design Pressure 0 - 65.5 barg
Operating Temperature 65 65 62 o
C
Design Temperature -20 - 90.3 o

C
Density 60.21 59.53 60.53 kg/m3

Viscosity 0.014 cP
Velocity 0.5 to 15.56 m/s

2.1.2. Gas Composition
Components Formula Gas (Mole %)
Methane CH4 64.3291
Ethane C2H6 14.7399
Propane C3H8 10.8887
i-Butane i-C4H10 1.5369
n-Butane n-C4H10 3.7221
i-Pentane i-C5H12 0.6919
n-Pentane n-C5H12 0.9012
n-Hexane - 0.6000
n-Heptane - 0.2461
n-Octane - 0.0808
n-Nonane - 0.0121
n-Decane - 0.0014
Nitrogen N2 0.4251
Hydrogen Sulphide H2S 0.0003
Water H2O 0.0148
Carbon Dioxide CO2 1.8096
2.1.3. Environmental Conditions

Description Minimum Maximum
Ambient Temperature -5 oC 55 oC
Humidity 17 % 65.9 %
Base Pressure 0 barg (1.01325 bara)
Base Temperature 15.56 oC
Atmospheric Pressure 1.01325 bara
2.1.4. Electrical Supplies

The system will be designed with the following electrical supplies:
Power Supply Voltage Frequency

Uninterruptible Power Supply 1 (UPS) 240Vac 50 Hz
Uninterruptible Power Supply 2 (UPS) 240Vac 50 Hz
Non-Uninterruptible Power Supply (NON-UPS) 240Vac 50 Hz
400V AC +/- 5%, 50Hz Three Phase with Neutral (TPN) supply for essential and non-essential services will be
provided by Basra Oil Company (BOC) / KBR.

A Utility /Panel Heat calculation schedule 33013M-01-E-0903-01 (Client Doc no MGP1-BOC1888PO001-C06-
0001) is issued that will detail power consumption on each provided power supply as well as to detail heat
calculations for the control panel.
2.2. Measurement Units

The units and resolution of the primary measurement variables are detailed below:
Note: Units are defined based on client Functional Specification for Custody Transfer Metering Skid - Sour &
Sweet Gas (as per client document no.PPP-GEN-KBR-IN-7739-0001).
Description Units Resolution

Mass Flow Rate Kg/h 12345.123
Gross Volume Flow Rate m3/h 12345.123
Standard Volume Flow Rate I @ 15.56oC Sm3/h 12345.123
o
Standard Volume Flow Rate II @ 15.56 C MMSCFD 1234.123
Energy Flow Rate GJ/h 12345.123
K-Factor Pls/m3 123456.1
M-Factor - 1.123456
Line Density kg/m3 123.123
Line Compressibility - 1.123456
Base Compressibility - 1.123456
Standard Density @ 15.56oC kg/Sm3 1.123456
Pressure barg 123.123
o
Temperature C 123.123
Calorific Value MJ/kg 1234.123
Mass Total tonne 1234567899.1
Gross Volume Total m3 1234567899.1
Standard Volume I @ 15.56oC Total Sm3 1234567899.1
Standard Volume II @ 15.56oC Total MMSCF 1234567899.1
Energy Total GJ 1234567899.1
Gas Components Mol % 12.12345
Velocity of Sound (VOS) m/s 123.123

2.3. Total Rollover
Rollover indicates the maximum number of the total before it rolls over to zero. This value is deliberately set to
11 digits to fit well within the numeric handling capacities of all the various computer equipment required to
display and report on totals in this package:
• S600+ Flow Computer (FC)

• Metering Supervisory Computer (MSC)
Decimal places in the totals are adjusted so that total will roll over at least after 1 year.
The other criterion for selecting the rollover values is Alderley’s Standard Practice, which is that cumulative
totals should not roll-over (reset to zero) more frequently than every three months.
2.4. Reference Documentation

List of drawings and documents that will be issued:
CLIENT DOC. NO. DESCRIPTION AFZE DOC. NO.

MGP1-BOC1888PO001-C01- PIPING & INSTRUMENTATION DIAGRAM (P&ID) - 33013M-01-D-0100-01
0001 CPF1 GAS METERING SKID
MGP1-BOC1888PO001-C15- CONTROL SYSTEM ARCHITECTURE DRAWING - CPF1
33013M-01-C-0902-01
0001 GAS METERING SKID
MGP1-BOC1888PO001-B01- PANEL CABINET GENERAL ARRANGEMENT
33013M-01-C-0920-01
0002 DRAWING - CPF1 GAS METERING SKID
MGP1-BOC1888PO001-C99- SOFTWARE DATABASE EXCHANGE TABLE (MODBUS
33013M-01-C-1605-01
0001 REGISTER) - CPF1 GAS METERING SKID
MGP1-BOC1888PO001-E07-
LOOP DIAGRAM - CPF1 GAS METERING SKID 33013M-01-C-0912-01
0001
MGP1-BOC1888PO001-E09- F&G DETECTOR DATASHEET- CPF1 GAS METERING
33013M-01-P-917-10
0013 SKID
MGP1-BOC1888PO001-C14-
F&G CE CHART - CPF1 GAS METERING SKID 33013M-01-P-1633-01
0001
MGP1-BOC1888PO001-F14- CONTAINERIZED CONTROL CUBICLE UPS SIZING
33013M-01-E-0933-01
0004 CALCULATION - CPF1 GAS METERING SKID
MGP1-BOC1888PO001-E09- UPS SYSTEM WITH BATTERY DATASHEET - CPF1 GAS
33013M-01-P-0917-11
0014 METERING SKID
MGP1-BOC1888PO001-E99-
HMI SCREEN SHOTS - CPF1 GAS METERING 33013M-01-C-0719-01
0001

2.5. Reference Specifications
Below list of Specifications from Basra Oil Company (BOC) / KBR. are used in the creation of this Functional
Design Specification:
Document Number Title Revision Date Received

PPP-CP1-KBR-IN-7303-0001 MATERIAL REQUISITION FOR CPF1 GAS
004 17 Feb 2022
METERING SKID
PPP-GEN-KBR-IN-7739-0001 FUNCTIONAL SPECIFICATION FOR
CUSTODY TRANSFER METERING SKID – 003 16 Feb 2022
SOUR & SWEET GAS
PPP-CP1-KBR-IN-2105-0009 DATASHEET FOR ULTRASONIC FLOW
003 16 Feb 2022
METER – CPF1 GAS METERING SKID
MGP1-BOC1888PO001-C01-0001 PIPING & INSTRUMENTATION
DIAGRAM 001 26 Apr 2023

2.6. Metering Standards
List of Metering Standards used by Alderley in the creation of this Functional Design Specification:
Standard Title Results Year
Calculate Density, Std Density and • Meter Density (kg/m3)

AGA-8 compressibility of a gas using the • Std. Density (Kg/Sm3) 2017
composition • Compressibility (-)
Measurement of gas by multipath Ultrasonic

AGA-9 • - 2017
Meters
AGA-10 Calculation of the speed of sound • Speed of Sound (m/s) 2003
Natural Gas - Calculation of calorific values, • Calorific Value (MJ/Kg)

ISO 6976 density, relative density, and Wobble index • Relative Density (-) 2016
from composition • Molar Mass (g/mol)
Manual of Petroleum Measurement

Standards Chapter 21.1 – Flow
API MPMS 21.1 • - 2013
measurement using Electronic Metering
systems – Electronic Gas Measurement
2.7. Calculation Accuracy

Flow computer calculations are performed to maximum precision with calculation accuracy better than +/-
0.001%.
2.8. Uncertainty Calculations

The Overall system uncertainty for observed volume flow rate is less than +/- 0.34 %.
The Overall system uncertainty for Standard volume flow rate is less than +/- 0.78 %.
3
3 The Overall system uncertainty for Mass flow rate is less than +/- 0.89 %.
The Overall system uncertainty for Energy flow rate is less than +/- 0.89 %.
For more details, please refer to Overall Uncertainty Calculations; Doc No: 33013M-01-T-1588-01/MGP1-
BOC1888PO001-F51-0003.

3. Metering Skid Overview
This section provides overview of the sweet gas metering skid, designed for Basra Oil Company (BOC) / KBR. ,
MAJNOON OIL FIELD EPCM SERVICE PROJECT.
3.1. Meter Run Components

This Metering System measures sweet gas on a continuous basis and consists of the following components which
are connected to Metering System:
Each of the Meter Run has:
o Inlet MOV
o USM Meter
o Pressure Transmitter
o Temperature Transmitter
o Cross-Over MOV (common between two-meter run)
o Outlet MOV
o Differential Pressure Transmitter
A Unit control panel is provided in non-hazardous area to interface with the skid. This panel consist of mainly:
Redundant FCs for each stream, Redundant MSCs, Redundant PLC System, etc.
Each Meter Run are connected to respective redundant S600+ Floboss Flow Computers in the metering control
panel. See Control System Overview Section for further details.
Two C9+ Gas Chromatographs are provided. Each GC is having two RS-485 Links.
3.2. 2 x 100% Metering System

The skid consists of 2 X 100% skid configuration, i.e., 1-meter run designed for providing enough skid flow and 1
meter run to be used as standby/Master (Check) meter (‘Z’ configuration). Standby / Master (Check) Meter’ is
termed as Check Meter in the document for the remaining sections.
3.3. Motor Operated Valve (MOV)

All MOVs of the metering skid are controlled/operated by the PLC system through MSC.
Following Signals for Status and Command are available from each MOV:
• Open Status
• Close Status
• Local/Remote Status
• Fault Status
• Open Command
• Close Command

3.4. Flow Meter
An Ultrasonic Meter Measures Gas volume flowrate. The meter works by transmitting ultrasonic pulses across
a pipe spool in a diagonal path. If no flow is present, then the difference in transit time of the upstream and
downstream pulses should be approximately zero. However, when a flow of product is introduced in one
direction, the pulse that is transmitted with the direction of flow will complete the diagonal path in a shorter
time than a pulse that is transmitted against the direction of flow. This difference between the upstream and
downstream pulses is used to measure the velocity. This velocity is converted into a gross volume rate by
multiplying by the cross-sectional area.
USM Functionality:
In this project, single dedicated USM is installed on each Stream.
Each USM meter provides Dual pulses for volumetric flow. Dual pulses from each USM meter are connected to
both S600+ Flow computers. Flow computer uses Dual Pulse input as a volumetric flow source.
Each USM meter has two RS-485 communication links. The 1st RS-485 Link is connected to respective Flow
computer for monitoring of some limited data from the USM. The 2nd RS-485 Link is connected to Metering
System via terminal server for monitoring of detail data from the USM.
Following communication settings will be set in Ultrasonic Meters:
USM COMMUNICATION DETAILS
Make & Model SICK, FLOWSIC600-XT
3 USM Output Signals 2 x Pulse output, 1x Digital Output

3
Link-1: RS-485 (2-wire) connected to FC for monitoring of some limited data.
Link-2: RS-485 (2-Wire) connected to terminal server for extended diagnosis from
Metering System.
USM Serial Port
Details Communication Protocol: Modbus RTU
Baud rate: 19200, 8 Data bits, 1 Stop bit, Parity: None.
Slave ID: 01

3.5. Gas Chromatographs
Chromatography is a method of separating and analysing components within a substance by passing it through
an absorbing material.
GC Functionality:
Gas Chromatographs will separate the sample gas into its components by the following method:
1. A precise volume of sample gas is injected into one of the analytical columns.
a. Each column contains a stationary phase (packing) that is either an active solid or an inert solid
support. This is then coated with a liquid phase (absorption partitioning).
2. The Sample Gas is moved through the column by means of a carrier gas.
3. The selective retardation of the components takes place in the column. This causes each component to
move through the column at a different rate.
a. Each component will take a unique length of time to move through the column. This is known
as its “retention time”. From this, the Composition of the Sample Gas can then be determined.
4. This separates the sample into its constituent gases and vapours.
Following communication settings are set for Gas Chromatograph used in this project:
GAS CHROMETOGRAPH COMMUNICTION DETAILS
Make & Model Honeywell, ENCAL-3000 (C9+)

Link-1: RS-485 (2-wire) connected to FC-A
Link-2: RS-485 (2-wire) connected to FC-B

GC Serial Port Details Modbus Slave RTU
Baud rate: 9600, 8 Data bits, 1 Stop bit, Parity: None
Slave ID: 01
1 X Ethernet Port 100 base for Diagnostic Purpose
Modbus Table for Serial Port Default by OEM
Note: In MSC, four modes of operation are available Auto / Chromat A / Chromat B / Keypad.
Detailed information on Gas Chromatographs can be found in later stage of this document.

4. Metering Control System
3
3
The diagram above is an overview of the sweet gas metering control system for Basra Oil Company (BOC) / KBR.
, MAJNOON OIL FIELD EPCM SERVICE PROJECT. The Control System Architecture Drawing 33013M-01-C-0902-
01 (Client Doc. No MGP1-BOC1888PO001-C15-0001) shows further details of various equipment’s in this system.

4.1. Metering Control System Functions
A Metering Control Panel (3-Bay) is provided for the sweet gas metering control system of Basra Oil Company
(BOC) / KBR. , MAJNOON OIL FIELD EPCM SERVICE PROJECT.
The Metering control panel consist of below major devices:
• Two Flow Computers in Duty/Standby configuration are provided for Metering Calculation purpose.
• A redundant PLC system (Redundant CPU + Redundant I/O) is provided for Metering skid’s Control and
Operation purpose.
• Two Metering Supervisory Computers (MSCs) in Duty/Standby configuration are provided for Operator
interface through dedicated panel mounted Monitors & Keyboards and ICSS interface (single Modbus
TCP/IP link from each MSC) through dedicated Fiber Optic converters and Fiber Optic Patch Panels.
• Two Network Switches are provided in redundant configuration to interface Flow computers and PLC
system to the MSCs.
• A Terminal server for both USMs diagnostics is connected to single network switch, with Software
Running on both MSC’s.
• GC Diagnostics software (RGC 3000) for diagnostic purpose installed on both MSC’s.
This section describes functionality of above major components.

4.2. Flow Computer Functions
Total two flow computers ‘FloBoss S600+’ (by Emerson) are provided in Duty/Standby configuration for the
sweet gas metering control system of Basra Oil Company (BOC) / KBR. , MAJNOON OIL FIELD EPCM SERVICE
PROJECT. Total one configuration is provided to satisfy the metering requirements as below:
• Dual Meter Run (Duty Meter Run and Standby/Check Meter Run) S600+ Gas USM Application installed
3
3 on CP000-5100-FC-401 & FC-CP000-5100-FC-402.
A summary of the functions performed by the S600+ Flow Computer is listed below. Detail information on these
functions can be found in later Stage of this document.
Signals per Flow computer

Number of Stream to interface Two [Stream1 (Duty Meter Run) + Stream2 (Standby/Check Meter Run)]
Signals from each USM Flow 1) 2 x Pulse for volume flowrate
Meter 2) 1 x Fault
3) 1 X RS-485 for online diagnosis via Flow Computer.
4) 1 X RS-485 for Extended diagnosis via Terminal Server.
Signals from each meter Run 1) 1 Nos. Pressure Transmitter (1-5 V)
2) 1 Nos. Temperature Transmitter (1-5 V)
Signal for flow measurement Dual pulse input from the USM meter is connected to both the FCs
GC Signal RS485 link from each GC for Gas Composition
Calculations
Flowrates 1) Gross Volume
2) Standard Volume (Metric & Imperial Units)
3) Mass
4) Energy (Metric)
Fiscal Totalisation Enable fiscal totalisation if all the flow parameters are within limit.
Following types of totalizers are considered.
1) Cumulative
2) Periodic (Hourly, Daily, Monthly and Maintenance)
Periodic of Flow Weighted 1) Hourly
Average 2) Daily
3) Monthly
Other Operations
Redundancy Duty / Standby
Master Meter (Check Meter) Inhibits Stream 2 fiscal totals during check metering (on the event of
stream 2 inlet valve closed signal status).
Report Current, Hourly, Daily, Monthly, Comparison, Constant Log, Alarm and
Event
Maintenance mode Evaluates mode based on ZERO flow status of each meter run
Time synchronization MSC will synchronise time to FC’s.
Check Metering FC performs check metering operation, on demand, once Clear to Check
received from PLC Digital Output.

Communications
Peer to peer Between FC-A & FC-B to establish redundancy.
Interface with MSC Redundant Ethernet links are provided from each FC to communicate
with MSC.

4.3. PLC Function (CP000-5100-PLC-401 & CP000-5100-PLC-402)
An ‘Allen Bradley’ PLC System (by Rockwell Automation) is provided with redundant CPU and redundant I/Os for
the sweet gas metering control system of Basra Oil Company (BOC) / KBR. , MAJNOON OIL FIELD EPCM SERVICE
PROJECT. Total one configuration is provided to satisfy the metering requirements.
3
3 A summary of the functions performed by the PLC system is listed below. Detailed information on below
functions can be found in later stage of this document.
Signals To/From PLC System

Digital Inputs 1) 5 MOVs X 1 Open Status
2) 5 MOVs X 1 Close Status
3) 5 MOVs X 1 Local/Remote Status
4) 5 MOVs X 1 Fault Status
5) 1 X Common UPS fault
6) 1 X Common 24V DC PSU fault
7) 1 X Common FAN fault
8) 1 X Common Panel Over Temperature
9) 2 X GC Sample line low flow
10) 2 X ESD from ICSS – Emergency Trip Signals
11) 1 X PSD from ICSS – Emergency Trip Signal
Digital Outputs 1) 5 MOVs X 1 Open Command
2) 5 MOVs X 1 Close Command
3) 1 X Clear to Check (For FCs)
4) 1 X Standby/Check Meter Run Inlet MOV Close status (For FCs)
Analog Input 1) 2 Stream X 1 Differential Pressure (4-20mA)
2) 2 GCs X 1 Calibration Gas Cylinder Pressure (4-20mA)
3) 2 GCs X 1 Carrier Gas Cylinder-A Pressure (4-20mA)
4) 2 GCs X 1 Carrier Gas Cylinder-B Pressure (4-20mA)
5) 1 X Moisture Analyser (4-20mA)
Functions
MOVs MOV’s monitoring and control operation with Auto and Manual mode
from MSC for open/close/align and de-align stream with necessary
interlocks.
GCs Monitor GC’s Carrier Gas and Calibration Gas cylinder’s pressure and
raise alarm on low pressure.
Monitor Flow Switch at GC’s sample inlet and raise alarm on low flow.
Moisture Analyser Monitor Moisture percentage for the Moisture analyser and raise
alarms as necessary.
Cabinet Utility Monitor Panel Utilities signals for UPS, PSU, Fan and Over
Temperature and raise alarms for the related signals.
Check Metering Interlock Observes MOVs alignment and provides signals to the flow computers
for check metering operation.
Communications
Interface with MSC Redundant Ethernet links are provided from each PLC chassis to
communicate with MSC.

4.4. MSC Function
Total two Metering Supervisory Computers (MSCs) ‘PowerEdge R350’ (by DELL) are provided with ‘Aveva Plant
SCADA’ (by Schneider) in Duty/Standby configuration for the sweet gas metering control system of Basra Oil
Company (BOC) / KBR. , MAJNOON OIL FIELD EPCM SERVICE PROJECT. Total one configuration is provided to
satisfy the metering requirements.
The MSCs provides Operator interface through dedicated set of panels mounted Monitors & Keyboards.
The MSCs provides ICSS interface (single Modbus TCP/IP link from each MSC) over single mode fiber optic cable
(provided by others) via individual Ethernet to Fiber Optic converters and individual Fiber Optic Patch Panel
installed in the Metering Cabinet.
A summary of the functions performed by the MSC is listed below. Detailed information on below functions
can be found in later stage of this document.
Functions
Graphical User Interface (GUI) Provides GUI on Panel Mount Monitors for Sweet Gas metering skids
by communicating with FCs and PLC for monitoring and Controlling
operations.
Valve monitoring Provides GUI for Monitoring & Controlling of all MOVs.
Gas Chromatograph Interface Over Ethernet for diagnostic purpose only.
Trending Trends for all necessary process parameters.
Alarms Provides all process, systems, and computer group alarm
with/without necessary filters.
Events Provides all the user and system generated events logs with/without
necessary filters.
Reports Provides defined Current, Periodic, Constants, Maintenance, Alarm
and Events reports.
Communications
Interface with FCs Communicates with the one set of duty/standby FCs over redundant
Ethernet links.
Report Printer Communicates with the Report printer over single Ethernet Link for
report printing.
Interface with PLCs Communicates with the 1 set of duty/standby PLCs over redundant
Ethernet links.
Interface with ICSS 1) Communicates with ICSS system (Provided by others) using single
Modbus TCP/IP Link from each MSC over individual single mode
fibre optic cable (provided by others) via individual Ethernet to
Fibre Optic converters and individual Fibre Optic Patch Panel
installed in the Metering Cabinet.
3
3 2) Communication with ICSS system via Hardwired trip signals,
Below mentioned hardwired trip signals are in parallel to both
stream inlet MOV closed commands from PLC. All 3 signals are
NC type, any one of the signal changes to NO, both stream inlet
MOV will get closed.
a) Level-1 ESD from ICSS
b) Level-2 ESD from ICSS
c) Level-1 PSD from ICSS

4.5. Ethernet Communication Network Details
Device TAG LAN-A LAN-B
MSC-A CP000-5100-MSC-401 10.30.13.11 10.30.14.11
MSC-B CP000-5100-MSC-402 10.30.13.12 10.30.14.12
FC-A CP000-5100-FC-401 10.30.13.21 10.30.14.21
FC-B CP000-5100-FC-402 10.30.13.22 10.30.14.22
PLC-A CP000-5100-PLC-401 10.30.13.31 10.30.14.31
PLC-B CP000-5100-PLC-401 10.30.13.32 10.30.14.32
Terminal Server CP000-5100-TS-401 10.30.13.51 N/A
Report Printer - 10.30.13.61 N/A
Maintenance Laptop - 10.30.13.71 N/A
DCS Link from MSC-A - TBA by ICSS N/A
3 DCS Link from MSC-B - N/A TBA by ICSS
3
GC-A CP000-5100-GC-434 10.30.13.101 N/A
GC-B CP000-5100-GC-454 N/A 10.30.14.101
Ethernet Switch-A CP000-5100-ES-401 10.30.13.2 N/A
Ethernet Switch-B CP000-5100-ES-402 N/A 10.30.14.2

5. Metering Panel
The Metering Panel is constructed/assembled as per Project specification / requirements. However,
where there is no specific requirement is described in the Project specification the panel will comply
with ‘Alderley Standard Panel Specification (AFZE-C-SP-00_00)’ detailed in Annexture-A.
The Metering Panel is made of 3 bays with an overall dimension of 800mm (Depth), 2400 mm (Width),
2100 mm (Height including plinth).
Equipment Fixing / Fitting Control Panel Project Specific Requirements
For Panel: 1 x 240VAC,50Hz NON-UPS and 2 x 240VAC,50HZ UPS power
feeders are provided. The UPS feeders shall be used as redundant to each
Incoming Supply
other for Panel critical loads, the NON-UPS shall additionally be used for
panel utilities (such as light, utility socket etc.)
Metalwork / Mechanical Control Panel Project Specific Requirements
3 Bays, each are of Rittal 800x800x2000mm-Colour RAL 7035 (TS Series),
Cabinet Qty. with Rittal 100mm plinth-Colour RAL 9005 (overall height is 2100mm
[Excluding lifting arrangements])
Cable Entry Cable entry is from bottom.

6. Metering System Bill of Material
6.1. Metering Control Panel Hardware
The following table defines the quantities of the major hardware components supplied with the
Metering Control Panel.
SWEET GAS CUSTODY TRANSFER METERING PANEL (CP000-MET-UCP-001)
Item Qty. Description Make Model
1 1 3 Bay Panel (Each bay of 800mmW x 800mmD Rittal TS series
x 2100mmH (with Plinth))
2 2 FloBoss S600+ Flow Computer Emerson S600+
3 2 Rack Mounted Metering Supervisory Computer Dell PowerEdge R350
4 1 Lot PLC System (Redundant CPU + Redundant I/O) Allen Bradley Control Logix
L71 Processor
5 2 22” Panel Mount Monitor Siemens SIMATIC IFP2200
6 2 Keyboard with Touchpad Cherry G84 5500
7 2 16 Port managed Ethernet Switch Moxa EDS-516A
8 1 4-port Terminal Server Moxa NPort-6450
10 2 Ethernet to Fiber converter Moxa IMC-21-S-SC
11 13 Signal Isolator (IS Type) MTL MTL-5541
12 2+1 24 VDC Power Supplies + Redundancy Module PULS QS40.241
YR80.242
6.2. Loose Supply Hardware

The following table defines the quantities of hardware components are loose supplied with the
Metering Control Panel.
Item Qty. Description Make Model

1 1 A4 Colour Laser Jet Report Printer HP M454dw
2 1 Maintenance Laptop DELL Latitude 5540

6.3. Software Licences & Media
The following table defines the quantities of the software components supplied for Metering Control
System.
Item Qty Description

1 2 MSC-SCADA Configuration Software: AVEVA Plant SCADA 2023 (Licence)
2 2 MSC-SCADA Configuration: Back-up
3 2 MSC Operating System: Windows Server 2022 (Licence)
4 1 Flow Computer Metering Configuration Software: CONFIG LITE (License)**
5 2 Flow Computer Metering Configuration: Back-up
6 1 PLC Configuration Software: Studio 5000 (License)**
7 1 PLC Configuration: Back-up
3 8 3 McAfee (Trellix) Antivirus software
3
9 1 USM Diagnostic Software
10 2 GC Diagnostic Software – RGC 3000
Note: ** marked software will be installed in the Maintenance Laptop.
Feature Tested Section 6

Functionality Tested Evidence: All Sections
Approved: Date: KBR/BOC:
Comments:

7. Flow Computer
7.1. Introduction
This section describes detailed functionality of the flow computer supplied for the Basra Oil Company
(BOC) / KBR. , MAJNOON OIL FIELD EPCM SERVICE PROJECT.
A Flow Computer is required to perform all the metering functionality. Flow Computer would
implement the calculation of flow rates and totals under operating and standard conditions.
For this project, the Emerson FloBoss S600+ Flow Computer will be used. It is a high-speed real-time
processing unit specifically designed for fiscal metering applications.
The S600+ configuration files are stored on the Metering Supervisory Computers (MSCs) through
supplied CD when required and can then be downloaded to the S600+ Flow Computers.
Field inputs can be interfaced to the S600+ Floboss flow computers.
On power up, all the S600+’s will boot up automatically and begin metering with no operator
intervention required. The Metering Supervisory Computers (MSCs) would automatically retrieve data
from the Flow Computers and continue to perform their supervisory functions.

7.2. Flow Computer details
Flow computer
Description CP000-5100-FC-401 CP000-5100-FC-402
Project Function Duty Meter Run + Duty Meter Run +
Standby / Check Meter Run Standby / Check Meter Run
Model S600+ S600+
LAN A 10.30.13.21 10.30.13.22
LAN B 10.30.14.21 10.30.14.22
Subnet (A&B) 255.255.255.0 255.255.255.0
Serial Link for RS485 2wire - RTU RS485 2wire - RTU

USM Baud rate: 19200 Baud rate: 19200
CP00-5100-FE-
421 8 Data bits, 1 Stop bit, None Parity 8 Data bits, 1 Stop bit, None Parity
3 USM Baud rate: 19200 Baud rate: 19200
3 CP00-5100-FE-
441 8 Data bits, 1 Stop bit, None Parity 8 Data bits, 1 Stop bit, None Parity
CP00-5100-GC- Baud rate: 9600 Baud rate: 9600
434
8 Data bits, 1 Stop bit, None Parity 8 Data bits, 1 Stop bit, None Parity
CP00-5100-GC- Baud rate: 9600 Baud rate: 9600
454
8 Data bits, 1 Stop bit, None Parity 8 Data bits, 1 Stop bit, None Parity
7.3. Displays
It is possible to observe the displays that are present on the S600+ in the following ways:
1. Local LCD Display on the S600+ Flow Computer
2. Web Interface - Accessed by a TCP/IP connection to the S600+ on either a laptop or a
Metering Supervisory Computer (MSC).
LCD
Display
View Key S600+
Function
Keys
Alarm Accept
LED Key
Menu Key Direction
Keys
Numeric
Keypad Operating
Keys

7.4. Local LCD Display
The S600+ has an LCD display from which all inputs and outputs may be viewed. A simple numbered
menu structure is used, where the front panel soft keys are used to navigate around the displays. The
screen below gives an example of the Local LCD Display on the S600+ Flow Computer providing the
user with data on the temperature reading of a Meter Run:
7.5. Keypad
7.5.1. Function Keys

There are 4 function keys on the S600+ (F1 – F4). These can be programmed as to be a shortcut to a
commonly used page.
7.5.2. Direction Key

The direction key is an oval, our-direction arrow key that allows the user to navigate displays and to
select parameters/data items to view or change.
7.5.3. Menu Key

The menu key allows the user to return to the previous menu (Move up one level of the display
hierarchy).
7.5.4. Numeric Keys

Numeric keys (0-9) allow the user to enter/change data and allow for navigation around the screens
on the S600+. The Minus key is used to enter negative numbers.
7.5.5. Operating Keys

• The exponent (EXPT) key can be used to enter numbers in scientific notation.
• The CLEAR key can be used to cancel or exit from a current operation and to return the user
to the previous data display.
• The Change (CHNG) key can be used to edit a database item within the S600+.
• The PRINT key is used to display the print menu.
• The display (DISP) key can be used to view a particular display path.

• The Enter key can be used to confirm that the user has entered data correctly into the
S600+.
7.5.6. Alarm Keys

The view key can be used to view any active alarms on the S600+. To accept an alarm, the accept
key is used. Acceptance of an alarm, states to the S600+ that the user has acknowledged the alarm.
7.6. Web Interface

The Web Interface allows the operator to view reports and alarm archives stored on the S600+ Flow
Computer. These reports shall be used for back-up purposes only. The primary reports for the
metering system shall be generated and archived by the Metering Supervisory Computers (MSC). The
screen below gives an example of the Web Interface on the MSC showing the same data on the
temperature reading of a Meter Run, which could be found on the S600+ Flow Computer (As seen in
the Local LCD Display Screenshot in the above section):
Access to the S600+’s web interface via this method is password protected. On this package, the web
interface can only be accessed at the engineer security level.
7.7. Changing Data

It is possible to change data within the Flow Computer in the following places:
1. Metering Supervisory Computer (MSC) - If a change is made; the changes of data are recorded
with date and time stamps and are available to be viewed via the Events Report.
2. Flow Computer – Changes are made on the front display, at the Engineer (eng-2) login level.
It is recommended that all modification of data is done at the Metering Supervisory Computer (MSC).
7.8. Alarms
An Alarm LED is provided to indicate the status of alarms on the flow computer:
Alarm LED Colour Indication
Green (Constant) Normal Operation (No Alarms activated)
Red (Flashing) Presence of an Alarm (Alarms have not been acknowledged)
Red (Constant) Alarms have been acknowledged but have not been cleared
Flow computer specific alarms are available to view on the Local LCD display on the S600+ as well as
the web interface.
Note: Alarm suppression has been enabled for the flowrates only in the flow computers.

7.9. Flow Computer Access Levels
Access to the S600+ displays is controlled by a password protected system. There are up to 9 different
access levels which can be configured for different displays. Two user levels are used.
User Type Functionality
Operator View all screens.
All operator functions as well as change calibration
Engineer
and scaling values and include operations
By default, a single user is assigned to each of the user types defined above. New users may be
assigned, or existing ones modified, by using the Floboss Config600 Configuration software. A
maximum of 50 users can be defined.
7.10. Flow Computer Operation
7.10.1. Calculation Method

The Volume flowrate is obtained from the USM via dual pulse signal. From these received meter
pulses, flow computers calculate the gross volume flow rate using the nominal K factor and meter
factors. This flowrate is compensated for temperature and pressure effect on the body of the USM in
flow computer.
Mass flow totals are calculated from the Gross volume and the meter density.
Energy flow totals are calculated from the Mass flow and calorific value.
The hourly, daily, and monthly totals are calculated from the cumulative totals.
7.10.2. Stream Status

The stream status is determined by the flow computer and may be any one of the following:
Status Description
UNDEFINED The status task is not running correctly
MAINT The flow computer has been put into Maintenance Mode
ON-LINE There is a flow path through the meter run AND the measured gross volume
flow rate is above the low flow cut-off limit.
OFF-LINE The measured gross volume flow rate is below the low flow cut-off limit.

7.10.3. Maintenance Mode
The following selection is available ‘Set’ (to enter maintenance mode) and ‘Clear’ (to exit maintenance
mode).
The individual stream should be put into Maintenance Mode when calculation or calibration tests are
to be carried out on the stream.
Entry and exit of Maintenance Mode is only possible if the stream status is Off-Line, flow rate is equal
to 0.0 m3/h and flow path is closed.
Whilst in Maintenance Mode the following occurs:
• Any flow registered is totalised into separate maintenance totalizers.
• Few alarms are suppressed i.e. Mass FR, L, H, Illegal Flow, meter density L H.
Maintenance Mode
Start
S600+ Flow
Computers
Cut off Value:

• Low Frequency Cut Off -> This is for Pulse
Generating Flow Meters
Is Meter Flow
Signal Less than No
Cut-Off Limit?
Yes
Maintenance
Totals
De-Activated
Yes (Exit from
Maintenance Mode) Yes (Enter in
Maintenance Mode)
End
Maintenance Mode Maintenance Mode

CLEAR SET
Maintenance
Totals
Activated

7.10.4. Totalisation
The primary totaliser measurement is the observed volume total which is received from the USM via
pulse signal. This total has a resolution of 0.1m3 and rollover at 9999999999.9
Each total is held as two discrete values, a displayed total, and a remainder. Increments are added
into the remainder and are only added into the displayed total when the remainder overflows.
The displayed total is truncated, i.e., not rounded up.
e.g.: Actual Total = 10.57382
Displayed Total = 10.5
Remainder = 0.07382
The total and remainder values are held in triple registers for increased security, i.e., a total of six
registers are used to represent the value of each total.
The system checks the tri-register cumulative totalizers each time they are incremented. If two
registers match but the third is different a tri-register partial fail alarm is raised, and the totalizer is
repaired by setting the third field to match the other two. If all three fields differ a tri-register total fail
alarm is raised, and totalisation is halted. Either of these alarms constitutes a major system fault.
The cumulative total represents the quantity of the gross volume, energy, and mass that has been
registered by the flow computer since its totals were last reset excluding any amount which has passed
whilst the flow computer has been in maintenance mode.
The hourly total represents the quantity of the gross volume, energy, and mass that has been
registered by the computer since the last hour end occurred excluding any amount which has passed
whilst the flow Computer has been in maintenance mode.
The daily total represents the quantity of the gross volume, energy, and mass that has been registered
by the computer since the last day end occurred excluding any amount which has passed whilst the
flow Computer has been in maintenance mode.
The monthly total represents the quantity of the gross volume, energy, and mass that has been
registered by the computer since the last month end occurred excluding any amount which has passed
whilst the flow Computer has been in maintenance mode.
The maintenance total represents the quantity of the gross volume, energy, and mass that has been
registered by the computer while it has been operating in maintenance mode.
Note: The maintenance totals are transferred to a previous maintenance mode total on exit of
maintenance mode and the current maintenance mode total is reset to zero.

7.10.5. Base Time
The Base Time specifies the hour at which the 24hr day ends. The value can be in the range 0 –23 hrs.
The Base Time for this system is set to 00:00 hrs.
At day end the current daily displayed total is copied into the previous day displayed total and the
current daily displayed total is set to zero. It should be noted that the associated current daily
remainder (which is not displayed) will remain unchanged.
The following example shows the transfer of totals over a five-day period; the values shown are those
recorded just after the relevant base times.
Day Sum of Daily Cumulative Total Remainder Daily Previous Day

Increments Displayed Total Total
1 10.57382 10.5 0.07382 10.5 0.0
2 11.66431 22.2 0.03813 11.7 10.5
3 7.14692 29.3 0.08505 7.1 11.7
4 8.19030 37.5 0.08108 8.2 7.1
5 9.99999 47.5 0.08107 10.0 8.2
7.10.6. Totals Reset

A total reset will reset all totals and therefore should be treated with extreme caution.
Totals may be reset by selecting ‘Totals Reset’ from the local flow computer display (following entry
of the high-level security code).

7.10.7. Duty / Standby Redundancy
The two redundant S600+ Flow Computers for each stream are designated A and B, with Flow
Computer A taking the role of the Duty Machine. Flow Computer B would take the role of Hot Standby.
In the event that the Flow Computer A fails, the 'Duty' role will automatically switch over to Flow
Computer B. Following this changeover, Flow Computer B will remain in the 'Duty' role until Flow
Computer A becomes healthy and the operator has manually switched the ‘Duty’ role back to Flow
Computer A. If the operator does not wish to manually switch over, then Flow Computer B will remain
in the ‘Duty’ role. The diagram below illustrates the possible scenarios for this process:
This architecture prevents the ‘Duty’ status from hunting between the two Flow Computers. Data and
commands will be downloaded to both Flow Computers in parallel to each other.

7.10.8. Check Metering
Check metering functionality is available in both the Flow computers and default it runs in the FC-A.
FC-B can be used for the check metering in case of failure of FC-A only. Check metering can only go
ahead if the following conditions are met:
Check Metering Sequence
Duty Stream is flowing (> low flow cut-off point).
Standby / Check Meter Stream inlet valve is CLOSED.
Flow Totalization INHIBITED on Check Meter Stream.
Duty Meter Stream is ALIGNED for CHECK METERING.
Flow, temperature, and pressure stabilization.
Flowrate deviation between Check Meter Stream and duty Meter Stream is less than 2%.
Check Meter Calculations started by user selectable time duration.
Check Metering operation completed.
Duty Meter Std. Vol. total − Check Meter Std. Vol.

Duty Meter Deviation (%) = ∗ 100
Check Meter Std. Vol. total
If all conditions are valid, then the operator may request to start a comparison. Following the start
command, totals on both Streams will be accumulated in separate comparison totals and a
comparison timer (configurable time) will start. When the timer has expired the flow computer will
raise a ‘Comparison Complete’ alarm.
The operator may now issue a comparison end command. On the stop being received a Check
Comparison Report will be generated. This report details the duration of the test, the totals registered
from each meter and the % difference between the duty totals and check Meter Stream totals.
Both streams MOVs alignment and dealignment is performed by the operator manually to perform
this operation for check metering.

7.10.9. S600+ Check Metering Flow Chart
The Flowchart that illustrates the Check Metering Sequence for the Flow Computer being used within
this System.

7.10.10. Alarm Transmitted to MSC
The alarms generated by flow computers are transmitted to MSC for display. Three types of alarms
(computer, system, process group) are only transmitted and details of these types can be referred in
Alarm sub section of Metering Supervisory Section of this document. Other two types (critical and
non- critical group) alarms are not detailed in this document as these are available in flow computer
only and not transmitted to MSC. However, if any critical or non-critical type alarms are in flow
computer, only MSC will alert and then it’s operator’s responsibility to take appropriate action by
viewing through webserver or front panel of flow computer.
7.10.11. Flow Computer Communications

7.10.11.1 Communications to Supervisory Computer
Dual Ethernet communication links are provided to allow process data and control commands to be
transferred between the flow computers and the MSC. The communication link uses the Modbus
TCP/IP protocol, with the flow computer as the slave device on the link.
7.10.11.2 PC-Setup Communications
Config transfer is provided on each MSC, Flow computer configuration files can be transferred to the
S600+ using the Ethernet connection to communicate with each S600+ in turn.
The application for the flow computer is stored in EEPROM (Flash memory) and is retained in the event
of power or battery failure.
Unique calculation constants and / or transmitter ranges are stored in battery supported RAM.
7.10.11.3 Local Printer Port
Each flow computer has a dedicated printer port that is not normally used, as reports are generated
at the MSC. However, if a printer or PC is connected to COM 3 on the rear of the flow computer a
number of reports are available, these include:
• Current Report
• Hourly Report
• Daily Report
• Monthly Report
• Maintenance Report
• Display Dump
• Constants Log
A report generated from a flow computer is identical in format to a report generated from any other
flow computer running the same software application.

7.11. Metering Run Instruments
Below is the table for instruments with type and quantity of signals for each Stream flow computers:
Instrument Stream FC Signal Type Qty

USM FC-A /FC-B Pulse Input 1 (Dual Pulse)
Digital Input (Fault) 1
Stream Pressure FC-A /FC-B Analog Input 1
Transmitter
Stream Temperature FC-A /FC-B Analog Input 1
Transmitter
The Alderley Metering Control System receives signals from these devices to perform Stream
monitoring and calculations. Alarms handling in the S600+ flow computers for all the signals.
Please refer Control System Architecture document no. 33013M-01-C-0902-01 Client doc no. MGP1-
BOC1888PO001-C15-0001 for more details.
7.12. Pulse Inputs Signals

7.12.1 USM Transmitter
The flow computer monitors dual pulse from the USM. The relationship between the number of pulses
received from the USM and the actual Gross volume passed is defined as the meter K-Factor in units
of pls/m3.
The Correction factor for the effects of temperature on the spool (CTSm), effects of pressure on the
spool (CPSm) will be calculated in flow computer, K-Factor (KF) and error factor curve are provided by
the USM manufacturer.
7.13. Analog Inputs Signals
7.13.1. Stream Pressure Transmitter

An Analogue input (4-20mA) from the Pressure transmitter is converted by high precision 250-ohm
resistor to 1-5V signal and wired to both Flow computers. On detection of the signal being out of
range, the override value will be used. There are two modes for these signals and can be selected by
the operator on the Alderley Metering Computer System on MSC.
• Measured
• Keypad
The Measured Mode is the Live Measured Value coming live from the instrument.
The Keypad Mode is the override value that is used if there is an issue with the instrument. This
override value is operator enterable.
On detection of the signal being out of range (out of range low (<3.5mA or .875v) and out of range
high (>21.5mA or 5.125v)), the mode of that input is automatically set to ‘Keypad/Fail’.
There are Operator Set points that can be set for Low Alarm and High Alarm Limits.

7.13.2. Stream Temperature Transmitter
An Analogue input (4-20mA) from the Temperature transmitter is converted by high precision 250-
ohm resistor to 1-5V signal and wired to both Flow computers. On detection of the signal being out of
range, the override value will be used. There are two modes for these signals and can be selected by
the operator on the Alderley Metering Computer System on MSC.
• Measured
• Keypad
The Measured Mode is the Live Measured Value coming live from the instrument.
The Keypad Mode is the override value that is used if there is an issue with the instrument. This
override value is operator enterable.
On detection of the signal being out of range (out of range low (<3.5mA or .875v) and out of range
high (>21.5mA or 5.125v)), the mode of that input is automatically set to ‘Keypad/Fail’.
There are Operator Set points that can be set for Low Alarm and High Alarm Limits.
7.14. Digital Inputs Signals

The voltage level for all the field/panel digital inputs is 24V DC.
7.14.1. USM Fault Signal

The flow computer monitors a digital input (one per USM) that indicates that the USM is healthy and
operating within tolerance. If this signal is de-activated, an alarm is raised and data from the USM
will not be used.

7.15. Signals Interfaced with Flow computers other than Meter runs
7.15.1. Duty / Standby Signal

Four digital inputs are used as part of the automatic Duty/Standby mechanism. These signals are:
• I AM DUTY
• I WANT DUTY
• PARTNER HEALTH
• I AM HEALTHY
• I AM ON
1. I Am Duty
Designates which computer is the duty machine. When it is set high, the computer is the duty
machine. When set low, the computer is the standby machine. This signal goes high after a Duty
request has been made if the relay is working properly.
2. I Want Duty
Whenever a computer needs to become the duty machine, it asserts this signal to make the relay
switch and set “I Am Duty” high.
3. PARTNER HEALTH
Receives digital input from Partner FC’s I AM HEALTHY output and identifies partner FC is healthy or
not.
4. I AM HEALTHY
The flow computer does the self-health check and generates this output as ‘I AM HEALTHY’. This
output will be observed by partner FC and to indicate ‘PARTNER HEALTH’.
5. I AM ON
The flow computer generates Digital output to indicate the FC power on status.

7.16. S600+ Connection Schedule for Flow Computers
7.16.1. P152 CPU: FC-A & FC-B

SERVICE P152 PCB SERVICE
24V DC
SUPPLY
LAN-A
WATCHDOG
(COMPUTER ALARM)
LAN-B
PEER TO PEER
FT-421
STREAM-1 USM
3
3 FT-441
STREAM-2 USM
GC-434
GC-454

7.16.2. P144 I/O: FC-A & FC-B
SERVICE P144 PCB SERVICE
SKT A SKT A
+15V
SUPPLY 1 8 ADC 1+ STR-1 Temperature (TIT-421)
DAC 1 OUTPUT 14 21 ADC 2+ STR-1 Pressure (PIT-421)
3 GROUND 2 9 ADC 3+
STR-2 Temperature (TIT-441)
3 SUPPLY 15
+15V 1-5V
22 ADC 4+
STR-2 Pressure (TIT-441)
DAC 2 OUTPUT 3 10 ADC 5+
GROUND 16 20 GND 0V DC
+15V
SUPPLY 4 11 ADC 6+
GROUND 5 12 ADC 8+
+15V 1-5V
SUPPLY 18 25 ADC 9+
GROUND 19 23 GND
SKT B 1mA SKT B

+12V
I+
4 8 ADC 11+
PRT 1 V+
1 0-1 V
4 - 20 mA 7 ADC 12+
INPUT V- 21 20 GND
I- 24 1mA +12V
30 PULSE OUT 1+
I+ 5 31 PULSE OUT 2+
PRT 2 V+ 2 0-1 V 32 PULSE OUT 3+
INPUT V- 22 33 PULSE OUT 4+
I- 25 1mA +12V
35 PULSE 1-4 COM
I+ 6 34 + PULSE
- OUTPUT 5
PRT 3 V+ 3 0-1 V 10 K
12
INPUT V- 23 9 + DENSITY
I- 26 10 K
27 - INPUT 1
STR-1 USM FAULT DIG IN 1- 13 10 + DENSITY

- INPUT 2
STR-2 USM FAULT DIG IN 2- 14 28
10 K
CLEAR TO CHECK DIG IN 3- 15 11 + DENSITY
- INPUT 3
STR-2 Inlet MOV Close Status DIG IN 4- 16 29
+24V DC COMMON + VE 17 36 DIG OUT 1+
DIG IN 5- 18 37 DIG OUT 2+
DIG IN 6- 19
SKT C
SKT C
37 DIG OUT 3+
DIG IN 7-
19 36 DIG OUT 4+
DIG IN 8-
18 35 COMMON GND
COMMON + VE
17 34 DIG OUT 5+
DIG IN 9-
16 33 DIG OUT 6+
DIG IN 10-
15 32 DIG OUT 7+
DIG IN 11-
14 31 DIG OUT 8+
DIG IN 12-
13 30 COMMON GND
COMMON + VE
12 29 DIG OUT 9+ I WANT DUTY
DIG IN 13- 11 28 DIG OUT 10+ I AM HEALTHY
DIG IN 14- 10 27 DIG OUT 11+ I AM ON
PARTNER HEALTH DIG IN 15-
9 26 DIG OUT 12+
0V DC
I AM DUTY DIG IN 16- 8 25 COMMON GND
+24V DC COMMON + VE 7 4 + DUAL PULSE

- CHANNEL 1
RAW PULSE + 24 23 STR-1 MTR USM PULSE-A
OUTPUT -
5 3 + DUAL PULSE
0V - CHANNEL 2 STR-1 MTR USM PULSE-B
22
2 + DUAL PULSE
21 - CHANNEL 3
STR-2 MTR USM PULSE-A
1 + DUAL PULSE
HIT HIT - CHANNEL 4 STR-2 MTR USM PULSE-B
20

7.17. Calculations
7.17.1. Flowrate Calculation

Standard conditions are 15.56 oC & 1.01325 bara.
7.17.1.1 Uncorrected Observed Volume Flowrate
Purpose: To calculate flowrate
Location: S600+ Flow Computer
𝑓
𝑞𝑣𝑎 = × 3600
𝐾𝐹
Where:
Term Definition Units
𝑞𝑣𝑎 Uncorrected Observed Volume Flowrate (m3/h)
𝑓 Meter Frequency (Hz)
𝐾𝐹 K Factor (pls/m3)
7.17.1.2 Gross Volume Flowrate

𝑞𝑣 = 𝑞𝑣𝑎 × 𝑉𝐶𝐹 × 𝐸
Where:
𝑞𝑣 Gross Volume Flowrate (m3/h)
𝑞𝑣𝑎 Observed Volume Flowrate (m3/h)
𝑉𝐶𝐹 Volume correction Factor -

𝐸 Linearization error curve Factor -

7.17.1.3 Mass Flow Rate
𝑞𝑚 = 𝑞𝑣 × 𝑅𝐻𝑂𝑚
Where:
𝑞𝑚 Mass Flowrate (kg/h)
𝑞𝑣 Gross Volume Flowrate (m3/h)
𝑅𝐻𝑂𝑚 Meter density Calculated using standard AGA-8 2017 (kg/m3)
7.17.1.4 Standard (15.56C) Volume Flow Rate-I

𝑞𝑚
𝑞𝑣𝑠𝑡𝑑 =
𝑅𝐻𝑂𝑠𝑡𝑑
Where:
𝑞𝑣𝑠𝑡𝑑 Standard volume flow rate I (Sm3/h)
𝑞𝑚 Mass Flowrate (kg/h)
𝑅𝐻𝑂𝑠𝑡𝑑 Standard (15.56 oC) density from AGA-8 2017 (kg/Sm3)
7.17.1.5 Standard (15.56C) Volume Flow Rate-II

𝑞𝑣𝑠𝑡𝑑𝑖𝑖 = 𝑞𝑣𝑠𝑡𝑑 × 0.0008475520

Where:
𝑞𝑣𝑠𝑡𝑑𝑖𝑖 Standard volume flow rate II (MMSCFD)
𝑞𝑣𝑠𝑡𝑑 Standard volume flow rate I (Sm3/h)

7.17.1.6 Energy Flowrate
𝑞𝑒 = (𝑞𝑚 × 𝐻𝐻𝑉)/1000
Where:
𝑞𝑒 Energy Flowrate (GJ/h)
𝑞𝑚 Mass Flowrate (kg/hr)
𝐻𝐻𝑉 Heating Value from ISO 6976 2016 @ (15.56,15.56) (MJ/kg)
7.17.1.7 USM Spool Correction Factor Calculations

Purpose: To calculate Volume correction factor (VCF)
Location: S600+ Flow computer
Equation Reference: FLOWSIC600XT IOM manual Section 2.2.4.2
𝑉𝐶𝐹 = 1 + 3 αT * 𝛥𝑇 + 3 αP * 𝛥𝑃
Where:
𝑉𝐶𝐹 Volume correction factor -

αT correction coefficient temperature, meter housing geometry (/C)
αP correction coefficient pressure, meter housing geometry (/barg)
𝛥𝑇 difference between operating temperature and reference calibration temperature (C)
𝛥𝑃 difference between operating pressure and reference calibration pressure (barg)
7.17.1.8 Deleted
7.17.1.9 Deleted

7.17.2. Total Calculation
7.17.2.1 Gross Volume Total Increment
Purpose: To calculate Total Increment
𝑃𝑢𝑙𝑠𝑒 𝑐𝑜𝑢𝑛𝑡
∆𝑄𝑣 = × 𝑉𝐶𝐹 × 𝐸
𝐾𝐹
Where,
∆𝑄𝑣 Gross Volume Total Increment (m3)
𝐾 K Factor (pls/m3)
VCF Volume correction factor -
𝐸 Linearization curve factor -
7.17.2.2 Mass Total Increment

∆𝑄𝑣 × 𝑅𝐻𝑂𝑚
∆𝑄𝑚 =
1000
Where:
∆𝑄𝑚 Mass Total Increment (t)
∆𝑄𝑣 Gross Volume Total Increment (m3)
𝑅𝐻𝑂𝑚 Meter density from AGA8 2017 (kg/m3)

7.17.2.3 Standard Volume (15.56C) Total I Increment
∆𝑄𝑚
∆𝑄𝑣𝑠𝑡𝑑 = × 1000
𝑅𝐻𝑂𝑠𝑡𝑑
Where:
∆𝑄𝑣𝑠𝑡𝑑 Standard Volume Total Increment (Sm3)
𝑅𝐻𝑂𝑆𝑡𝑑 Standard Density at reference conditions (kg/Sm3)
7.17.2.4 Standard Volume (15.56C) Total II Increment
∆𝑄𝑣𝑠𝑡𝑑𝑖𝑖 = ∆𝑄𝑣𝑠𝑡𝑑 × 0.0008475520

Where:
∆𝑄𝑣𝑠𝑡𝑑𝑖𝑖 Standard volume Total II Increment (MMSCF)
∆𝑄𝑣𝑠𝑡𝑑 Standard volume Total I Increment (Sm3)
7.17.2.5 Energy Total Increment (GJ)

∆𝑄𝑒 = ∆𝑄𝑚 × 𝐻𝐻𝑉

Where:
∆𝑄𝑒 Energy total I increment (GJ)
𝐻𝐻𝑉 Heating Value from ISO 6976 2016 @ (15.56,15.56) (MJ/kg)

7.17.3. Density Calculations
7.17.3.1 Calculated Meter Density – AGA8 2017
Purpose: To calculate Meter Density
Reference: AGA8-2017 Part-2 GERG 2008
𝑀𝑃1 × 100000
𝑅𝐻𝑂𝑚 =
𝑍×𝑅 ×(𝑡1 + 273.15)
Where:
3 Term Definition Units

3
𝑍 Compressibility factor of gas at line conditions -
𝑃1 Meter Pressure Bar(a)
𝑅 Gas constant 8.314510 (J/mol - K)

𝑡1 Meter temperature (C)
𝑀 Mixture molar mass (kg/mol)
𝑅𝐻𝑂𝑚 Meter density (kg/m3)
7.17.3.2 Compressibility at Operating Conditions - AGA8 2017

Purpose: To calculate Compressibility
3 Reference: AGA8-2017 Part-2 GERG 2008
3 Location: S600+ Flow Computer
𝑃1 × 100000
𝑍=
𝑑𝑚 ×𝑅×(𝑡1 + 273.15)
Where:
𝑍 Compressibility factor of gas at Metering condition -
𝑃1 Absolute Pressure at Meter Conditions Bar(a)
𝑅 Gas constant 8.314510 (J/mole - K)

𝑡1 Meter temperature (C)
𝑑𝑚 Molar density of gas calculated from AGA8 equation 24 using Brent’s method (moles/m3)

7.17.3.3 Calculated Standard Density – AGA8-2017 Part-2
Purpose: To calculate Standard Density
3
3 Location: S600+ Flow Computer
𝑀𝑃𝑠𝑡𝑑 × 100000
𝑅𝐻𝑂𝑠𝑡𝑑 =
𝑍𝑠𝑡𝑑 𝑅 (𝑡𝑠𝑡𝑑 + 273.15)
Where:
𝑍𝑠𝑡𝑑 Compressibility factor of gas at Standard base conditions -
𝑃𝑠𝑡𝑑 Absolute Pressure at Standard Base Conditions Bar(a)
𝑅 Gas constant 8.314510 (J/mole - K)

𝑡𝑆𝑡𝑑 Temperature at Base Conditions (C)
𝑀 Mixture molar mass (kg/mol)
𝑅𝐻𝑂𝑠𝑡𝑑 Standard density (kg/Sm3)
7.17.3.4 Table References AGA 8

Purpose: For Reference
Reference: COMPONENT MOLAR MASS (Refer to table A.1 AGA8-2017).

7.17.4. AGA 10 Calculations
7.17.4.1 Calculated Velocity of Sound
Velocity of sound will be calculated using AGA10.
7.17.4.2 Conversion from barg to bara
Purpose: conversion
𝑝1 = 𝑝 + 1.01325
Where:
𝑃 Pressure (bar g)
𝑃1 Pressure (bar a)
7.17.5. ISO6976 Calculations

7.17.5.1 Ideal Heating Values on molar basis (ISO 6976-2016)
Purpose: To calculate Ideal Heating Value on Molar basis
Reference: ISO 6976-2016 equation 2
N
(Hc)G (t1)= ∑ xj * [(Hc)°G ]j (t1)
°
1
Where,

(𝐻𝑐)°𝐺 (𝑡1) Ideal-gas gross molar-basis calorific value of the mixture (MJ/kmol)
[(𝐻𝑐)°𝐺 ]𝑗 (𝑡1) Ideal gross molar-basis calorific values of component j (MJ/kmol)
𝑋𝑗 Mole fraction of component j -
7.17.5.2 Ideal Heating Value (ISO 6976-2016) – Mass basis

(𝐻𝑐)°𝐺 (𝑡1)
(𝐻𝑚)°𝐺 (𝑡1) =
𝑀
Where,
𝑁
𝑀 = ∑ 𝑥𝑗 𝑀𝑗
𝑗=1

Where,

(𝐻𝑐)°𝐺 (𝑡1) Ideal-gas gross molar-basis calorific value of the mixture (MJ/kmol)
(𝐻𝑚)°𝐺 (𝑡1) Ideal-gas gross mass basis calorific value of the mixture (MJ/kmol)
𝑀 Molar mass of the mixture (g/mol)
𝑀𝑗 Mole mass of component j from Table 1 (g/mol)
𝑥𝑗 Mole fraction of component j -
7.17.5.3 Compression Factor (ISO 6976)

Purpose: To calculate compression factor
Reference: ISO 6976
2
21
𝑝2
Z(𝑡2 ,𝑝2 ) = 1 - ( ) 𝑋 [∑ x 𝑗 ∗ 𝑠𝑗 (𝑡2 , 𝑝0 )]
𝑝0
𝑗
Where:
Z(𝑡2 ,𝑝2 ) Compressibility factor at the metering reference conditions -
𝑝0 Constant absolute pressure values 101.325 kpa
𝑝2 Reference pressure kpa
x𝑗 Mole fraction of component j -
𝑠𝑗 (𝑡2 , 𝑝0 ) Summation factor from table-2 of ISO6976-2016 calculation standard -
7.17.5.4 Table References ISO 6976 2016

TABLE 1: COMPONENT MOLAR MASS (Refer to ISO 6976, 2016)
TABLE 2: COMPONENT SUMMATION FACTORS @ reference conditions (Refer to ISO 6976 2016).
TABLE 3: COMPONENT CALORIFIC VALUES FOR THE IDEAL GAS ON A VOLUMETRIC BASIS (Refer to
ISO 6976, 2016) @ combustion reference conditions superior.

7.17.6. Flow Weighted Averages (Stream Level)
Separate flow weighted averages (Stream 1, Stream 2) are calculated for the hourly, daily & Monthly
periods from cumulative gross volume total. Averages are available for:
• Meter Temperature
• Meter Pressure
• Meter Density
• Standard [email protected] C
• Calorific Value (real superior)
• Gas compositions
Purpose: To calculate flow weighted averages

FWAc = (FWAp * UV)/(UV + DV) + (Cv * DV)/(UV + DV)
Where:
FWAc Current flow weighted average -
FWAp Previous flow weighted average -
DV Gross volume from this calculation cycle m3
UV Total Gross volume from previous calculation cycle m3
Cv Current value of variable -

7.17.7. Flow Weighted Averages (Station)
The Flow weighted average for individual stream is performed in the flow computer. The raw
parameters such as Pressure, Temperature, Meter Density, Standard Density, Heating Value & Gas
compositions for each stream will be sent to the MSC.
MSC will perform the station averages based on station formulae as below:
Pstation average
[(VStream 1 x PFlow average Stream 1)] + [(VStream 2 x PFlow average Stream 2 )]
=
[VStream 1 + VStream 2]
Where:
Pstation average Station Flow Weighted Average for Parameter -
VStream 1 Standard Volume (Sm3) Total for Stream 1 (Previous Period). Sm3
PFlow average Stream 1 Flow weighted Average for Parameter (Stream 1) -
VStream 2 Standard Volume (Sm3) Total for Stream 2(Previous Period). Sm3
PFlow average Stream 2 Flow weighted Average for Parameter (Stream 2) -
7.17.8. Component Averaging

The individual mol% of all components downloaded to the S600+ flow computer will be flow weighted
averaged over an hour and day period with respect to overall Standard volume flowrate.
FWAmol% j =
 X  Qv 100
j
 Qv
Where:
FWAmol%j Flow weighted mol% of component j -
Xj Mol fraction for component j -
Qv Standard volume total Sm3
Qv Standard volume increment since the last scan. Sm3

7.17.9. Linearization Curve Calculation
Purpose: The flow computer configuration implements a 10-point error linearization curve, which
calculates an error against Observed volume flowrate received from the meter. It does this by
interpolating between the Observed volume flowrate and error points immediately above and below
the measured Observed volume flowrate.
Linearization for USM meter has been implemented in Flow computers.
Reference:
Location: S600+ Meter Run Flow Computer
The calculated error (%) is determined as follows: -
(𝑋 − 𝐿𝑜𝑤𝑒𝑟 𝑋𝑝 ) 𝑋 (𝐻𝑖𝑔ℎ𝑒𝑟 𝑌𝑝1 − 𝐿𝑜𝑤𝑒𝑟 𝑌𝑝1 )

𝐸𝐶𝑎𝑙𝑐 = + 𝐿𝑜𝑤𝑒𝑟 𝑌𝑝1
(𝐻𝑖𝑔ℎ𝑒𝑟 𝑋𝑝 − 𝐿𝑜𝑤𝑒𝑟 𝑋𝑝 )
100
𝑌𝑝1 =
(𝑌𝑝 + 100)
Where:
𝐸𝐶𝑎𝑙𝑐 Linearization curve factor based on the curve Error % that corresponds to flow -
𝑋 Meter pulse input frequency (Hz)
XP Frequency Co-ordinates (Hz)
YP Error Co-ordinates (%)
7.17.10. Unit Conversion Factors (Metric to Imperial Units)

Conversion Conversion Factor Conversion Factor C
Implementation
1 m3 = 35.3146667 Cubic Feet Flow computer 35.3146667
(CF)
1 BTU = 1055.05585 Joule (J) Flow computer 1055.05585

Comments:

8. Gas Chromatograph
8.1. Introduction
This section describes detailed functionality of the Gas Chromatograph supplied for the Basra Oil
Company (BOC) / KBR. , MAJNOON OIL FIELD EPCM SERVICE PROJECT.
Total two Gas Chromatographs are provided in the Analyser Shelter.

The Gas Chromatographs are Honeywell’s Encal 3000 (C9+). Component data from each GCs are the
read by both flow computers by individual Serial (RS-485) links from each GC.
8.2. Basic Function

A summary of the flow computer’s functions is:
• Check the communication link from both GCs.
• Periodically check whether a new analysis is available (from GC) and retrieve
the analysis.
• Raise alarms if the composition received is out of range.
• Normalise the received composition to 100%.
• Define limits for gas compositions.
• C9+ Split.
8.3. Communication To Gas Chromatograph

Both Serial (RS-485) ports from each GC are connected to both Flow computers. Once analysis is ready,
unnormalized components are retrieved from the GC, normalized by FC & downloaded to in-use
compositions.
The communication settings are:
• Modbus Address: 1
• Comms Protocol: Modbus RTU
• Electrical Protocol: RS 485
• Baud rate: 9600
• Parity : None
• Data Bits : 8
• Stop bits : 1
The Duty-FC acts as the master device and initiates all data transfers with the chromatograph. GC-A
data is used as default else if communication fails with GC-A then will switch to the GC-B.

8.4. GC Operating Mode
Following modes of operation are available,
a. AUTO
b. CHROMAT-A
c. CHROMAT-B
d. KEYPAD
In Auto mode, the duty-FC will use the live Chromat-A data as long as there are healthy
communications, the analysis has not timed out, and the un-normalised total is within the entered
limits. If any of these conditions are not true then the ‘data in use’ will default to the Chromat-B live
data as long as there are healthy communications, the analysis has not timed out, and the un-
normalised total is within the entered limits. If any of these conditions are not true for Chromat-B
live composition, then the ‘data in use’ will default to the keypad / override composition.
After failure of the Chromat-A or Chromat-B, if any Chromat become healthy again then switch over
‘data in use’.
In Chromat-A mode, the ‘data in use’ will always come from the Chromat-A as long as there are healthy
limits. If any of these conditions are not true, then the ‘data in use’ will default to the manually
entered override (Keypad) data.
In Chromat-B mode, the ‘data in use’ will always come from the Chromat-B as long as there are healthy
limits. If any of these conditions are not true, then the ‘data in use’ will default to the manually
entered override (keypad) data.
In Keypad mode, the ‘data in use’ will always come from the manually entered override data.

8.5. GC Analysis Data Handling
11.2.1 GC Data Map
The flow computer reads the following data:
3
3 Register Format Description Units
3058 16-bit INT Data Ready Flag -
3059 16-bit INT Analysis / Calibration Flag -
7001 32-bit Float Methane (C1) Mol %
7002 32-bit Float Ethane (C2) Mol %
7003 32-bit Float Propane (C3) Mol %
7004 32-bit Float i-Butane (iC4) Mol %
7005 32-bit Float n-Butane (nC4) Mol %
7006 32-bit Float i-Pentane (iC5) Mol %
7007 32-bit Float n-Pentane (nC5) Mol %
7015 32-bit Float Hydrogen Sulphide (H2S) Mol %
7008 32-bit Float Hexane (C6) Mol %
7009 32-bit Float Heptane(C7) Mol %
7010 32-bit Float Octane (C8) Mol %
7011 32-bit Float Nonane (C9) Mol %
7012 32-bit Float Decane (C10) Mol %
7013 32-bit Float Nitrogen (N2) Mol %
7014 32-bit Float Carbon Dioxide (CO2) Mol %
7035 32-bit Float Gas Density -
7038 32-bit Float Total Mol % Mol %
11.2.2 C9+ Proportions

The chromatographs provide a composition breakdown to C9, and the heavier components are
included within this component. When the composition data is received this percentage, split is used
to derive the composition data for C9 and C10. C9+ splits initialized as below:
Component % split
C9 100
C10 0

11.2.3 Calibration Flag (REG 3059)
If the Chromatograph Controller performs a calibration analysis, then calibration function is identified
by the FC with ‘Calibration Flag’ and displayed on MSC. Gas composition observed during calibration
are not normalised/ used/ printed or downloaded to the flow computers.
If any alarm is raised post calibration, further investigation will need to be done via the available
diagnostic port as to the cause of failure.
11.2.4 Calculation Method

Typically, 21 different components are downloaded to the flow computer. As the AGA8 calculation at
the flow computer only recognizes 20 components the flow computer combines some components
together to obtain the 20 required by the AGA 8 calculation.
iPentane = iPentane + neopentane
11.2.5 Override Composition

The provisions to enter a gas composition that will be used in the event of live chromatograph failure.
This override composition can also be manually selected. This data is used to override the values that
would normally have been received from the chromatograph.
11.2.6 Normalization
It should be noted that normalisation takes place irrespective of whether the data received from the
chromatograph is already normalised.
100 - Sa
The normalisation factor Nf =
Su
NCi = UCi X Nf
where:
Nf = Normalization factor
Sa = Sum of additional components
Su = Sum of un-normalised components
NCi = Normalised Gas Component i
UCi = Un-normalised Gas Component i

8.6. Chromatograph Alarms
The FC generates following alarm from the data received from each Gas Chromatograph:
• GC Link fail alarm
The duty-FC communicates to the GCs.
• Stream Analysis timeout alarm
The duty-FC will raise an alarm if a new analysis (calibration analysis excluded) is not received within
a default period set to 30-minute. Analysis timeout period is User-configurable from MSC.
• Composition totals out of limits alarm
An Un-normalised total (mol %) is retrieved from the GC. This value is checked to be within a low and
high limit. If this value is not witing the low or high limit, then the ‘Composition total out of limit’ alarm
is raised. Low and High limit for un-normalised total (mol%) are User-Configurable from MSC.
• GC diagnostic link fail alarm.

3
3
Both GC are connected to MSC for diagnostic via ethernet switch. Alarm will be generated if any
diagnostic link communication fails.

Comments:

9. Programmable Logic Controller
9.1. Introduction
This section describes detailed functionality of the Programmable Logic Controller (PLC) supplied for
the Basra Oil Company (BOC) / KBR. , MAJNOON OIL FIELD EPCM SERVICE PROJECT.
An Allen Bradley redundant ControlLogix PLC system is provided, consisting of two processor racks
(configured in Enhanced Redundant mode) and redundant I/O cards for the metering skid. The PLC
provides valves processing.
PLC performs the following monitor and control functions:
• Control and monitor MOVs from the MSC.

• Performs Change line on failure functionality.
• Provide interlock checks and alarms for MOVs.
• Manual control of individual MOVs from the MSC. (Open/Close)
• Provide MOV’s and Stream’s status information to the MSC.
• Provide panel utility related status information to the MSC.
• Provide GC’s Carrier and Calibration Gas Cylinder’s Pressure to the MSC.
• Provide GC’s sample line flow switch status to the MSC.
• Provide Moisture Analyser status information to the MSC.
• Provide Stream differential pressure status information to the MSC.
• Provide hardwire status of clear to check interlock to the flow computers.
• Provide hardwire status of stream-2 inlet MOV’s close status interlock to the flow
3
3 computers.
• Provide control for auto alignment & dealignment of MOV for Check metering
operation in Z- configuration.
9.2. PLC Digital Input Signals

The voltage level for all the field/panel digital inputs is 24V DC.
9.2.1. MOV Status

There are four inputs associated with each MOV; these are Open, Close, Local/Remote status and Fault
status. The Valve open, close status limit switches are NC type to detect the open / close conditions
of valve, when valve is open, the valve open status limit switch will give 'OFF' and when valve is closed
the valve close limit switch will give 'OFF'. therefore, when valve is in moving position both open &
close feedback will be ON. From the open and close inputs, the MOV’s status is derived as follows:
MOV Status Open Input Close Input Colour
Open OFF ON GREEN
Close ON OFF RED
Travel ON ON YELLOW
Undefined OFF OFF MAGENTA

An alarm is raised if the valve status is ‘Undefined’.
The ‘Local/Remote’ selector switch of MOV represents the ‘Local’ or ‘Remote’ status for the MOV. 0V
DC (open circuit) indicates ‘Local’ position of selector switch and 24VDC (close circuit) indicates
‘Remote’ position of selector switch. An alarm ‘Local Mode’ is raised for individual MOV, if the
‘Local/Remote’ selector switch is in ‘Local’ position.
The ‘Fault’ input represents the ‘Fault/Healthy’ status of MOV. 0V DC (open circuit) indicates ‘Fault’
status of the MOV and 24VDC (close circuit) indicates ‘Healthy’ status of the MOV. An alarm ‘Fault’ is
raised if the ‘Fault’ input is 0V DC (open circuit).
An alarm ‘Uncommand Move’ is raised by the PLC for individual MOV, if the MOV goes in to the ‘Travel’
position without any command (open/close), while it is in ‘Remote Manual’ or ‘Remote Auto’ mode.
An alarm ‘Local Move’ is raised by the PLC for individual MOV, if the MOV goes in to the ‘Travel’
position, while it is in ‘Local’ mode.
An alarm ‘Timeout’ is raised if valve does not reflect commanded position during pre-configured
timeout-time. This timeout-time for each MOV’s can be configured by user from the MSC.
9.2.2. Panel Over Temperature

This signal is wired to the PLC from panel thermostats (connected in series & typically set to 35°C). If
the input is 0V DC (open circuit) an alarm ‘Panel Over Temperature’ is raised.
9.2.3. PSU 24V DC Fail

One signal indicates failure of one of the panels 24V DC power supplies. If the input is 0V DC (open
circuit) an alarm ‘24V DC PSU Fail’ is raised.
9.2.4. UPS 240V AC Fail

One signal indicates failure of one of the panels 24V DC power supplies. If the input is 0V DC (open
circuit) an alarm ‘24V DC PSU-2 Fail’ is raised.
9.2.5. FAN Fail

This signal is wired to the PLC from Air Flow sensors (connected in series). If the input is 0V DC (open
circuit) an alarm ‘Fan Fail’ is raised.
9.2.6. GC-A Sample Flow Low

This signal is wired to the PLC from Flow switch installed in the GC-A’s sample inlet line. If the input is
0V DC (open circuit) an alarm ‘GC-A Sample Flow Low’ is raised.
9.2.7. GC-B Sample Flow Low

This signal is wired to the PLC from Flow switch installed in the GC-B’s sample inlet line. If the input is
0V DC (open circuit) an alarm ‘GC-B Sample Flow Low’ is raised.

9.2.8. Level-1 ESD signal from ICSS
This Signal is wired to PLC from ICSS for monitoring and alarming of Level-1 ESD signal from ICSS. This
signal is directly hardwired to close the inlet MOVs of both stream in parallel to PLC digital output for
closing both stream inlet MOVs.
9.2.9. Level-2 ESD signal from ICSS

This Signal is wired to PLC from ICSS for monitoring and alarming of Level-2 ESD signal from ICSS. This
9.2.10. Level-1 PSD signal from ICSS

This Signal is wired to PLC from ICSS for monitoring and alarming of Level-1 PSD signal from ICSS. This

9.3. PLC Digital Output Signals
The voltage level for all the digital outputs is 24V DC.
9.3.1. MOV Commands

The PLC provides controlled Output (Open/Close Command) to MOVs. Each command causes the
output to pulse ON for 5 seconds. The minimum time between pulses is 5 seconds OFF. The valve-
controlled outputs are as follows:
• Open Command
• Close Command
After an open or close command, the PLC will monitor the valve status. If the valve has not reached
the requested position within the required time, then an alarm is ‘Timeout’ raised.
9.3.2. Clear to Check

The PLC provides one output for the Flow Computers. This output indicates that Stream-1 is aligned
for Check Meter operation. This digital output of the PLC is wired to the FC’s digital input. This digital
input to the FC used as an interlock for ‘Check Metering’ operation. This output will be ON only if all
the following conditions are met.
Stream – 1 aligned for check metering.
• Stream-1 Inlet MOV is open.

• Crossover MOV is open.
• Stream-2 (Check Meter) Outlet MOV is open.
• Stream-2 (check Meter) Inlet MOV is close.
• Stream-1 Outlet MOV is Close.
9.3.3. Check Meter Inlet MOV Close Status

The PLC provides one output for the Flow Computers. This output is generated, once the standby
stream-2 / check meter run’s inlet MOV is ‘CLOSE’. This digital output of the PLC is wired to the FC’s
digital input. This digital input to the FC used to stop fiscal total for standby/check meter. Refer below
table for more information:
Condition Stream-2 Station
Fiscal Totalizer Fiscal Totalizer
If stream 2 inlet valve is closed Deactivates Does not consider Stream
2
If stream 2 inlet valve is not Activates Consider Stream 2
closed

9.4. PLC Analog Input Signals
All Analog Input to the PLC are 2-Wire, 4-20mA.
9.4.1. GC- Carrier & Calibration Gas Cylinder Pressure

Pressure transmitter is provided on the GC’s Carrier & Calibration Gas Cylinders for monitoring and
alarm purpose. When the live value of Carrier/Calibration Gas Cylinder’s Pressure is below the low
setpoint, then an alarm is raised for ‘Carrier/Calibration Gas Cylinder Pressure Low’. Below mentioned,
six analog signals are considered:
3 • GC-434 Carrier Gas Cylinder Pressure. (CP00-5100-PIT-435)

3 • GC-434 Calibration Gas Cylinder-A Pressure. (CP00-5100-PIT-436)
• GC-434 Calibration Gas Cylinder-B Pressure. (CP00-5100-PIT-437)
• GC-454 Carrier Gas Cylinder Pressure. (CP00-5100-PIT-455)
• GC-454 Calibration Gas Cylinder-A Pressure. (CP00-5100-PIT-456)
• GC-454 Calibration Gas Cylinder-B Pressure. (CP00-5100-PIT-457)
9.4.2. Moisture Analyser

Single analog signal for Moisture analyser is provided for monitoring and alarm purpose. High and Low
alarms are considered for this analog signal.
Moisture Analyser (CP00-5100-MA-434)
9.4.3. Stream Differential Pressure

Total two analog signals (one for each Stream) differential Pressure signals are provided for monitoring
and alarm purpose. Only, high differential pressure alarms are considered for these analog signals.
• Differential Pressure across stream-1 (CP00-5100-DPT-424)
• Differential Pressure across stream-2 (CP00-5100-DPT-444)

9.5. Communication To MSC
The PLC is having dual (redundant) communication links from each CPU Chassis. So, total of four
communication links are there. These links are connected to MSC’s dual (redundant) communication
ports over the redundant Local Area Network provided by two (redundant) Ethernet switches.
Description PLC-A PLC-B

Main Functions Main function of the PLC is to Monitor and Control MOVs with interlocks.
The PLC will also Monitor below parameters:
• Raise Panel health Alarms
• Raise GC’s Utility Alarms
Model An Allen Bradley redundant ControlLogix PLC system is provided, consisting of two
processor racks (configured in Enhanced Redundant mode) and redundant I/Os.
Communication Ethernet
Protocol
LAN A(Port 1) 10.30.13.31 10.30.13.32
LAN B(Port 2) 10.30.14.31 10.30.14.32
Subnet (A&B) 255.255.255.0 255.255.255.0
9.6. Operation & Control

The PLC accepts and validates control commands from the MSC. All the MOVs command buttons
enable only if the Interlock for individual command is valid.
To allow all MOVs commands, PLC to provide valid & require interlock status to the MSC for correct
operation of MOVs.
MOV’s command is disallowed if related interlocks are not satisfied.

9.6.1. MOV Interlocks
During normal operation, the PLC performs interlock checks as per following table.
COMMAND ACCEPTANCE CONDITIONS

Stream Stream Stream Check
Check Allowed Command
MOVs Inlet Outlet Crossover Outlet Check
Inlet MOV in REMOTE AUTO /
MOV MOV MOV MOV Running
Status REMOTE MANUAL
Status Status Status Status
Not
Stream Close Close X X No OPEN
Fault
Inlet
X Close Close X X No CLOSE
Open Not Fault Close X X No OPEN
Stream Open Not Fault Open Close Open No OPEN (DE-ALIGN)
Outlet Open X Close Open Open No CLOSE
Open X Open Close Open No CLOSE (ALIGN)
Stream Open Open Not Fault Close Open No OPEN (ALIGN)
Crossover Open Open X Close Close No CLOSE (DE-ALIGN)
Check Open Open Close Not Fault Close No OPEN
Inlet Open Open Close X Close No CLOSE
Open Open Close Open Not Fault No OPEN
Check Open Open Close Close Not Fault No OPEN (ALIGN)
outlet Open Open Close Open X No CLOSE
Open Open Open Close X No CLOSE (DE-ALIGN)
Note: “X” represents, any state of MOV does not have any effect.
The above interlock table shows “True” conditions of each MOV’s opening/closing command for open,
close, align and de-align meter run control.
Apart from the above table, following conditions (general interlocks) are must to operate the MOV
from the MSC:
• MOV must be in Remote Mode.
• MOV should not be in Fault state (for Opening condition only).
• MOV should not be in Time-out state.

9.6.2. Stream Commands
If any of the meter MOVs are set to “Local” mode or in “Remote-Manual” mode during the meter run
commands, then the “Interlock Violation” alarm will be raised, and meter run command is disallowed
from the MSC.
If any MOV fails to reach the requested position within the MOV time-out period, then an alarm will
be raised, and the open meter sequence will be abandoned.
9.6.3. Stream Open Control

The PLC accepts commands from the MSC to control the meter MOVs. On receipt of an open
command, the PLC initiates the following sequence to open the meter run:
1. An open command is issued to the meter inlet MOV with checking the prover Cross Over MOV
and meter outlet MOV close status.
2. Once the meter inlet MOV is open, an open command is issued to the meter outlet MOV.
9.6.4. Stream Close Control

The PLC accepts commands from the MSC to control the meter MOVs. On receipt of a close command,
the PLC initiates the following sequence to close the meter run:
1. A close command is issued to the meter outlet MOV with checking the prover Cross Over MOV
close status and inlet MOV open status.
2. Once the meter outlet MOV is closed, a close command is issued to the meter inlet MOV.
9.6.5. Stream Align Control

To align a meter run, following sequence to be done with the Interlocks. INTERLOCK VALIDATION: -
1. Ensure that the Duty Stream is ‘On-line’. i.e.: Duty Stream inlet and outlet valves are open.
2. Standby / Check meter stream inlet valve is closed.
3. Open, Check meter run’s outlet valve.
4. Open, Stream Cross Over valve.
5. Close, the Duty Stream outlet valve.
Now, the stream is ‘Aligned’ & ‘Clear to Prove’ digital output will be SET (energized). This output is
wired to the flow computer/s.
9.6.6. Stream De-Align Control

To de-align a meter run, following sequence to be done with the Interlocks mentioned in INTERLOCK
VALIDATION: -
1. Ensure that the meter run is ‘Aligned’.
2. Open, Duty Stream outlet valve. As the Duty stream outlet valve starts opening the ‘Clear to
Prover’ digital output will be RESET (de-energized)
3. Close, Check meter run’s outlet valve.
4. Close, Stream Cross Over valve.

9.6.7. Stream Status
The PLC determines a status for the Stream in reference to the status of the Stream MOV’s (Inlet,
outlet & Cross Over) and standby/check Stream MOV (Inlet, Outlet) as below and generates an
“Integer” value. These values will be passing to the MSC, to show the stream status by PLC:
Meter Status Integer Description
(By PLC) Value to
MSC
Transit 0 Any one of the streams MOV/s is in transit state
Open 1 Inlet & outlet MOVs are open and Cross Over MOV is closed
Close 2 All stream MOVs are closed
Aligned to 3 Stream inlet & Cross Over MOV and Check outlet MOV are open
Check and stream outlet & Check Inlet MOV is closed
Illegal 4 Inlet MOV is closed and off take or outlet, or both are open
Standby 5 Inlet open and off take & outlet both closed
Undefined 11 Any one of the Stream/Crossover MOV is/are Undefined.
The MSC will also indicate the Stream’s Status in combination with the Stream status received from
the Flow computer. This Stream Status is explained later in MSC section of this document.
9.6.8. Change Stream on Failure

This functionality can be set to 'On' or 'Off' From the MSC and controlled from PLC. This feature can
only be set to 'On', if the duty stream has ‘on-line’ status and the stand-by stream meets both
'Available' criteria mentioned below, otherwise MSC will turn ‘Off” this functionality.
This functionality would be automatically set to ‘Off ’ by PLC, if any of the stream is in
‘Aligned/Proving’ or Any MOV (Inlet, Outlet and Cross-over) from all the streams is not set to Remote
and Auto Mode.
When this functionality is set to ‘On’ and if duty streams failure occurs, PLC will open the standby
stream first. Once the standby stream’s opening is established, the 'failed' stream will be closed.
Following are mentioned related definitions:
Definition of stream failure
• Meter Fault Alarm Raised
• PT Fail
• TT Fail
MSC will provide ‘stream Fail’ status to PLC as per above mentioned ‘Definition of stream failure’.
––

Definition of Available by operator
This availability is set by operator on MSC after observing following conditions:
• All MOVs of both streams are set to Remote and Auto Mode from MSC.
• Standby stream is Not in Maintenance Mode.
Definition of Available by logically
• No alarms raised in the 'Computer' alarm group.
If this feature is ever invoked the alarm 'Automatic Change Stream Active' is raised and the mode is
set to 'Off' by PLC after completing the function to prevent cycling of streams.
9.7. PLC Connection Schedule

An Allen Bradley redundant ControlLogix PLC system is provided, consisting of two processor racks
(configured in Enhanced Redundant mode) and a bus with Redundant I/O cards for the metering skid,
with card configuration as below:
9.7.1. PLC System Card Layout
Primary PLC Secondary PLC

Slot No. 0 1 2 3 4 5 6 Slot No. 0 1 2 3 4 5 6
1756-EN2TR
1756-EN2TR
1756-EN2T
1756-EN2T
1756-EN2T
1756-EN2T
1756-PB72
1756-PB72
1756-RM2
1756-RM2
1756-L71
1756-L71
EMPTY
EMPTY
EMPTY
EMPTY
Redundant
I/O Bus #1
Slot No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13
1715-OB8DE
1715-OB8DE
1715-OB8DE
1715-OB8DE
1715-OB8DE
1715-OB8DE
1715-AENTR
1715-AENTR
1715-IB16D
1715-IB16D
1715-IB16D
1715-IB16D
1715-IB16D
1715-IB16D
Slot No. 14 15
1715-IF16
1715-IF16

9.7.2. PLC I/O Assignment
Digital Input Card I/O Bus 1 Slot 2 & 3

Pin. Signal
Description Tag* PLC Address
3 No. Source
3
Ch1+ Stream-1 Inlet MOV open status MZSH-421 Bus_1:2:I.Data.0 Field to PLC
Ch2+ Stream-1 Inlet MOV close status MZSL-421 Bus_1:2:I.Data.1 Field to PLC
Ch3+ Stream-1 Inlet MOV L/R Status MILH-421 Bus_1:2:I.Data.2 Field to PLC
Ch4+ Stream-1 Inlet MOV Fault Status MZA-421 Bus_1:2:I.Data.3 Field to PLC
Ch5+ Stream-1 Outlet MOV open status MZSH-423 Bus_1:2:I.Data.4 Field to PLC
Ch6+ Stream-1 Outlet MOV close status MZSL-423 Bus_1:2:I.Data.5 Field to PLC
Ch7+ Stream-1 Outlet MOV L/R Status MILH-423 Bus_1:2:I.Data.6 Field to PLC
Ch8+ Stream-1 Outlet MOV Fault Status MZA-423 Bus_1:2:I.Data.7 Field to PLC
Stream-1 Crossover MOV open
Ch9+ MZSH-431 Bus_1:2:I.Data.8 Field to PLC
status
Ch10 Stream-1 Crossover MOV close
MZSL-431 Bus_1:2:I.Data.9 Field to PLC
+ status
Ch11 Stream-1 Crossover MOV L/R
MILH-431 Bus_1:2:I.Data.10 Field to PLC
+ Status
Ch12 Stream-1 Crossover MOV Fault
MZA-431 Bus_1:2:I.Data.11 Field to PLC
+ Status
Ch13
Spare Bus_1:2:I.Data.12
+
Ch14
+
Ch15
+
Ch16
+
Panel
Ch1- 0 V DC -
Supply
to : : :
Ch16 Panel
0 V DC -
- Supply
*All tags are prefixed with CP000-5100-

3
Pin. Signal
Description Tag* PLC Address
3 No. Source
Ch1+ Stream-2 Inlet MOV open status MZSH-441 Bus_1:4:I.Data.0 Field to PLC
Ch2+ Stream-2 Inlet MOV close status MZSL-441 Bus_1:4:I.Data.1 Field to PLC
Ch3+ Stream-2 Inlet MOV L/R Status MILH-441 Bus_1:4:I.Data.2 Field to PLC
Ch4+ Stream-2 Inlet MOV Fault Status MZA-441 Bus_1:4:I.Data.3 Field to PLC
Ch5+ Stream-2 Outlet MOV open status MZSH-443 Bus_1:4:I.Data.4 Field to PLC
Ch6+ Stream-2 Outlet MOV close status MZSL-443 Bus_1:4:I.Data.5 Field to PLC
Ch7+ Stream-2 Outlet MOV L/R Status MILH-443 Bus_1:4:I.Data.6 Field to PLC
Ch8+ Stream-2 Outlet MOV Fault Status MZA-443 Bus_1:4:I.Data.7 Field to PLC
Ch9+ GC-A Sample Low Flow Switch FS-433 Bus_1:4:I.Data.8 Field to PLC
Ch10
GC-B Sample Low Flow Switch FS-453 Bus_1:4:I.Data.9 Field to PLC
+
Ch11
+
Ch12
+
Ch13
+
Ch14
+
Ch15
+
Ch16
+
Panel
Ch1- 0 V DC -
Supply
to : : :
Ch16 Panel
0 V DC -
- Supply

Pin.
Description PLC Address Signal Source
No.
Ch1+ Panel Over Temperature Bus_1:6:I.Data.0 UCP to PLC
Ch2+ PSU (24V DC) Fail Bus_1:6:I.Data.1 UCP to PLC
Ch3+ UPS (240V AC) Fail Bus_1:6:I.Data.2 UCP to PLC
Ch4+ Fan Fail Bus_1:6:I.Data.3 UCP to PLC
Ch5+ Level-1 ESD signal from ICSS Bus_1:6:I.Data.4 ICSS to PLC
Ch6+ Level-2 ESD signal from ICSS Bus_1:6:I.Data.5 ICSS to PLC
Ch7+ Level-1 PSD signal from ICSS Bus_1:6:I.Data.6 ICSS to PLC
Ch8+ Spare Bus_1:6:I.Data.7
Ch9+ Spare Bus_1:6:I.Data.8
Ch10
+
Ch11 Bus_1:6:I.Data.1
Spare
+ 0
Spare
+ 1
Spare
+ 2
Spare
+ 3
Spare
+ 4
Spare
+ 5
Ch1- 0 V DC - Panel Supply
to : : :
Ch16
0 V DC - Panel Supply
-

Digital Output Card I/O Bus 1 Slot 8 & 9
Pin.
Description Tag* PLC Address Signal Source
No.
Stream-1 Inlet MOV Open
Ch1+ MHSH-421 Bus_1:8:O.Data.0 PLC to Field
command
3 Stream-1 Inlet MOV Close Bus_1:8:O.Data.
3 Ch2+ MHSL-421 PLC to Field
command 1
Stream-1 Outlet MOV Open Bus_1:8:O.Data.
Ch3+ MHSH-423 PLC to Field
command 2
Stream-1 Outlet MOV Close Bus_1:8:O.Data.
Ch4+ MHSL-423 PLC to Field
command 3
Stream-1 Crossover MOV Open Bus_1:8:O.Data.
command 4
Stream-1 Crossover MOV Close Bus_1:8:O.Data.
command 5
Bus_1:8:O.Data.
Ch7+ Spare
6
Bus_1:8:O.Data.
Ch8+ Spare
7
0V For Ch1 & 2 - Panel Supply
V1+ For Ch1 & 2 - Panel Supply
*All tags are preffixed with CP000-5100-

Pin. Tag*
No.
Stream-2 Inlet MOV Open Bus_1:10:O.Data
3 command .0
3 Stream-2 Inlet MOV Close Bus_1:10:O.Data
command .1
Stream-2 Outlet MOV Open Bus_1:10:O.Data
command .2
Stream-2 Outlet MOV Close Bus_1:10:O.Data
command .3
Bus_1:10:O.Data
Ch5+ Spare
.4
Bus_1:10:O.Data
Ch6+ Spare
.5
Bus_1:10:O.Data
Ch7+ Spare
.6
Bus_1:10:O.Data
Ch8+ Spare
.7
*All tags are preffixed with CP000-5100-

Pin.
No.
Ch1+ Clear To Check Bus_1:12:O.Data.0 PLC to FC
Stream-2 Inlet MOV Close Status
Ch2+ Bus_1:12:O.Data.1 PLC to FC
Output
Ch3+ Spare Bus_1:12:O.Data.2

Analog Input Card I/O Bus 1 Slot 14 & 15
Pin.
Description Tag* PLC Address Signal Source
No.
GC-434 Calibration Gas Cylinder
Ch1+ PIT-435 Bus_1:14:I.Data.0 Field to PLC
Pressure
GC-434 Carrier Gas Cylinder-A
Pressure
GC-434 Carrier Gas Cylinder-B
Pressure
GC-454 Calibration Gas Cylinder
Pressure
GC-454 Carrier Gas Cylinder-A
Pressure
3
3 GC-454 Carrier Gas Cylinder-B
Pressure
Ch7+ Moisture Analyzer MA-434 Bus_1:14:I.Data.6 Field to PLC
Ch8+ Stream-1 Differential Pressure DPT-424 Bus_1:14:I.Data.7 Field to PLC
Ch9+ Stream-2 Differential Pressure DPT-444 Bus_1:14:I.Data.8 Field to PLC
Ch10
+
Ch11
+
Ch12
+
Ch13
+
Ch14
+
Ch15
+
Ch16
+
Ch1- 0 V DC - Panel Supply
to : : :
Ch16
0 V DC - Panel Supply
-

Comments:

10. Metering Supervisory Computer (MSC)
10.1. Introduction
All data from the field is sent to the Metering Supervisory Computer (MSC) via the Flow Computers
and PLC.
On this project, Redundant MSC are provided.
The MSC will generate graphical user interface data, produce reports, provide trending facilities, and
archive data.
The MSC is rack mount server computer and uses the Schneider AVEVA PLANT SCADA 2023
application which runs on the Microsoft, Windows platform.
10.2. MSC Function

A summary of the functions performed by the Metering Supervisory Computers within this system are
listed below.
• Provides GUI for Sweet gas metering skid by communicating with FCs & PLCs.
• Provides GUI for Monitoring & Controlling of all MOVs.
• Provides GUI for USM & GC live values.
• Provides GUI for check metering operation.
• Provides all the user and system generated events logs.
• Provides defined Current, Periodic, Constants, Maintenance, Check comparison, Alarm and
Events reports.
• Performs time synchronization to all flow computers.
• Trends for all necessary process parameters.
• Provides all process, systems, and computer group alarm.
• Dual TCP/IP links (one from each server) to communicate and exchange data with client DCS.
• Gas chromatograph RGC3000 software is installed for maintenance and configuration purposes.
10.3. MSC Summary

The table below details the hardware specification of MSCs:
Project Function Metering Supervisory Computer
Manufacturer Dell
Model PowerEdge R350
Memory Size 4 X 16 GB RAM
Hard Disk 1 1.2TB RAID 1 with HDs 2
Hard Disk 2 1.2TB RAID 1 with HDs 1
Removable Media DVD-RW

10.3.1. MSC Security
Access to changing the information on the MSC displays are controlled by a password protected
system. There are different User Access Levels, of which they are detailed in the table below:
User Type Functionality

(default username)
Operator View all screens and do changes in parameter values that will not affect
integrity of metering.
Engineer Change calibration and scaling values
Supervisor Access to date and time, add new users
Administrator For ALDERLEY engineers & B designated personnel only
10.3.2. MSC Virus Protection

Virus protection software is designed to prevent viruses, worms, and Trojan horses from causing
damage to a computer as well as remove any malicious software that has already infected a computer.
The MSC computer will be exposed to potential Viruses during its life cycle. McAfee Trellix Antivirus is
used on MSC to protect them and the systems they are connected to.
10.3.3. MSC Report Archiving

The following reports are available to be printed from the MSC archive.
Report Type No. of Reports *
Hourly 999 per station
Daily 999 per station
Monthly 999 per station
Composition Report 999 per station
Daily Alarm 31 per station
Daily Event 31 per station
* These are minimum archive periods.
The facility is provided to back up reports to Compact Disc, this is a manual function.

10.3.4. Metering Supervisory Computer, Software Summary
The table below details the software that has been supplied with MSC, providing version numbers,
installation dates as well as a functional description of the software.
Software/ Storage
Functional Description Supplier Supplied
Firmware Name Media
Windows Server 2022,

Operating System Microsoft Yes
Standard 64 Bit
AVEVA PLANT SCADA
SCADA/HMI Application Schneider Electric Yes
2023
Installed on
S600+ Configuration Emerson Process
Config600 Transfer Yes MSC
Transfer Management
McAfee Trellix Complete
Antivirus McAfee Yes
Endpoint Protection
HP Printer Drivers Printer HP Yes
10.4. MSC Alarms

The Alderley Metering Control System generates several alarms pertaining to the status of skid
instruments, control panel devices, processes, and calculations. Alarms are ordered by time.
However, it is possible to sort and filter the alarms.
All Alarms available on this system by the MSC or S600+ Flow Computer can be found in the HMI.
Alarm Category/ Severity Category/ Description

Severity Code
Process P Alarms Relating to any Process Condition having Exceeded

a Preconfigured Alarm Threshold
System S Alarms Relating to a Failure of an Instrument or an
Abnormal Condition Having been Detected
Computer C Alarms Relating to the Detection of an Internal Fault in any
of the Control Panel Devices

10.4.1. Process Alarms
This type of alarm indicates that a process condition has crossed an alarm threshold. These alarms
include High and Low alarms.
Alarm Generated By Description

Stream X Pressure Low FC A/B The in-use Meter X Pressure is below the operator
entered low alarm limit
Stream X Pressure High FC A/B The in-use Meter X Pressure is above the operator
entered high alarm limit
Stream X Temperature Low FC A/B The in-use Meter X Temperature is below the operator
Stream X Temperature High FC A/B The in-use Meter X Temperature is above the operator
HHV Low FC A/B The calculated Higher Heating Value is below the operator
HHV High FC A/B The calculated Higher Heating Value is above the operator
Stream X Density Low FC A/B The in-use Density is below the operator entered low
alarm limit
Stream X Density High FC A/B The in-use Density is above the operator entered high
alarm limit
Stream X Standard Density FC A/B The calculated Standard Density is below the operator
Low entered low alarm limit
Stream X Standard Density FC A/B The calculated Standard Density is above the operator
High entered high alarm limit
Stream X Standard Volume FC A/B The standard volume flow rate is below the operator
Flow Rate Low entered low flow limit
Stream X Standard Volume FC A/B The standard volume flow rate is above the operator
Flow Rate High entered high flow limit
Gross Volume Flow Low FC A/B The flow rate is below the operator entered Low flow limit
Gross Volume Flow High FC A/B The flow rate is above the operator entered high flow
limit
Mass Flow Rate Low FC A/B The Mass flow rate is below the operator entered low
flow limit
Mass Flow Rate High FC A/B The Mass flow rate is above the operator entered high
flow limit
Stream X Differential Pressure PLC The Stream differential Pressure is above the operator
High entered high alarm limit
GC-X Sample line Flow Low PLC GC-X Sample Line Flow Low switch activated
GC-X Calibration Gas Cylinder PLC GC-X Calibration Gas Cylinder Pressure is below the
Pressure Low operator entered Low alarm limit

GC-X Carrier Gas Cylinder-X PLC GC-X Carrier Gas Cylinder -X Pressure is below the
Pressure Low operator entered Low alarm limit
Stream-X USM Path-X SNR FC A/B Path X average signal to noise ratio is above the operator
high entered High alarm limit
Stream-X USM Path-X VOS FC A/B Path X velocity of sound is above the operator entered
high High alarm limit
GC-X Mole % XXXX Low FC A/B GC Mole%(each component) is below the operator
entered Low alarm limit
GC-X Mole % XXXX High FC A/B GC Mole%(each component) is above the operator
entered High alarm limit
GC-X Mole % Total Low FC A/B GC Mole% Total is below the operator entered Low alarm
limit
GC-X Mole % Total High FC A/B GC Mole% Total is above the operator entered High alarm
limit
GC-X Analysis Timeout FC A/B New analysis has not been received from GC within time.
Stream -X MOV Timeout PLC Stream valve does not reach to other position after
command issued from MSC via PLC

10.4.2. System Alarms
This type of alarm indicates that there has been a failure of an instrument, or an abnormal condition
has been detected. These Alarms include Instrument Over Range, Under Range Alarms and
Communications failure Alarms etc.
Alarm Generated Description

By
Stream-X Pressure Under Range FC A/B The input signal is below 3.5mA
Stream-X Pressure Over Range FC A/B The input signal is above 20.5mA
Stream-X Temperature Under Range FC A/B The input signal is below 3.5mA
Stream-X Temperature Over Range FC A/B The input signal is above 20.5mA
Diff. Pressure across stream-X Under PLC The input signal is below 3.5mA
Range
Diff. Pressure across stream-X Over PLC The input signal is above 20.5mA
Range
GC-X Calibration Gas Cylinder PLC The input signal is below 3.5mA
Pressure Under Range
GC-X Calibration Gas Cylinder PLC The input signal is above 20.5mA
Pressure Over Range
GC-X Carrier Gas Cylinder-X Pressure PLC The input signal is below 3.5mA
Under Range.
GC-X Carrier Gas Cylinder-X Pressure PLC The input signal is above 20.5mA
Over Range.
FC Critical Fault FC A/B Internal fault generated by flow computer e.g. calc
fail.
FC Non-Critical Fault FC A/B Internal fault generated by flow computer
USM-X Fault FC A/B The hardwired digital input for USM-X Fault has been
activated
USM-X Comm Fail FC A/B Serial Communications with the USM is failed
GC-X Comm Fail FC A/B Serial Communications with the GC is failed
MOV-X Fault PLC The hardwired digital input for MOV-X Fault has been
activated
MOV-X Undefined Position PLC MOV both Open & Close feedback inputs are active
MOV-X Uncommanded Move PLC MOV status changed when no Command is issued
when in Remote
Panel Over Temperature PLC Any of the thermostat is above 35 ‘C
Fan Fail PLC Any of the Fans are not working
DC Fault PLC DC 1 or DC 2 24DVC power failure
UPS Fault PLC 120 VAC UPS power failure
FC X MSC LAN X Comms Offline MSC Three or more consecutive messages to the specified
device have failed
PLC X MSC LAN X Comms Offline MSC Three or more consecutive messages to the specified
device have failed

10.4.3. Computer Alarms
This type of alarm indicates that a computer has detected an internal fault or that its watchdog output
has been activated. These Alarms include Cold Start of S600+ Flow Computer, ROM fail, Totals
Corrupted, etc.
Alarm Alarm Generation Description

Location
Battery Fail* FC A/B The voltage has fallen below the point at which data will
(SYS HOST BATT FAIL) be retained during a power dip/
Total Fail* FC A/B All three total tri-registers disagree
(SYS HOST TOT CORR)
Warm Start FC A/B The computer has performed a warm start probably due
(SYS HOST WARM ST) to a power dip.
Cold Start FC A/B The computer has been re-initialised
(SYS HOST COLD ST)
Note: *Alarms only generates in case of actual failure and unable to demonstrate during test.

10.5. MSC Reports
The following reports are displayed at the MSC and are available for printing on the report printer if
required.
• Current Status Report (manual)

• Hourly Report (automatic)
• Daily Report (automatic)
• Monthly Report (automatic)
• Yearly Report (automatic)
• Check Comparison Report
• Maintenance Report (automatic)
• Parameter / Constants Log Report (manual)
• Chromat A/B Analysis Report (automatic)
• Active Alarm Report (manual)
• Daily Alarm Report (automatic)
• Daily Event Report (automatic)
3 • Daily Summary Report - Quality (Automatic)
3
• Daily Summary Report -Quantity (Automatic)
Automatically generated reports can be disabled from printing, if required; however, they are always
archived.
10.5.1. Report Archiving

The following reports are available to be printed from the MSC archive.
Report Type No. of Reports *

Hourly 999 per station
Daily 999 per station
Monthly 999 per station
Summary 999 per station
Daily Alarm 31 per station
Daily Event 31 per station
* These are minimum archive periods.

Reports can be backed up to Compact disc if required (engineer only), though no prompt is given to
carry out this function – it could be done as part of the monthly system housekeeping.

10.5.2. Report Descriptions
Current Status Report
This report details the current process conditions.
Hourly Report
This report is generated every hour and is a summary of the flow through each Meter Run for the
last hour.
Daily Report
This report is generated every day (day end hour initialised to 0hrs) and is a summary of the flow for
the last 24 hours.
Monthly Report
This report is generated every month (Month end hour initialised to 0hrs) and is a summary of the
flow for the last month.
Yearly Report
This report is generated every year (year-end hour initialised to 0hrs) and is a summary of the flow
for the previous year.
Maintenance Report
This report is generated following exit of maintenance mode & and is a summary maintenance
totalizer.
Parameter Report / Constants Log Report
This log details the operator constants and configuration settings currently in use. A separate report
is available for each device in the system. Note: Constant logs for the S600+ flow computer is
available via the S600+ web interface.
Chromat Analysis Report
This single daily report with each transaction logged will be provided rather than a separate report
for each transaction.
Active Alarm Report
This report details all alarms currently raised on the system and can be printed on request.
Daily Alarm Report
The alarms that occur during a day are archived for later reference. These can be printed on request.
Daily Event Report
Each event that takes place on the system in a day is logged.

10.5.3. Current Status Report
CURRENT REPORT
LOCATION: AAAAAAAAAAAAAAAA REPORT INITIATED: DD/MM/YYYY HH:MM:SS
CURRENT PROCESS DATA Stream 1 Stream 2 Station

Meter Tag AAAAAAAAAA AAAAAAAAAA
Meter Run Status AAAAAAAAAA AAAAAAAAAA
Meter Temperature (°C) xxx.xxx xxx.xxx
Meter Pressure (barg) xxx.xxx xxx.xxx
Meter Density (kg/m3) xxx.xxx xxx.xxx
Standard Density @ 15.56°C (kg/Sm3) xxx.xxxxxx xxx.xxxxxx
K-Factor (pls/m3) xxxxxx xxxxxx
M-Factor x.xxxxxx x.xxxxxx
CV (15.56,15.56) (MJ/kg) xxxx.xxx xxxx.xxx
CURRENT FLOW RATES

Gross Flow (m3/h) xxxxx.xxx xxxxx.xxx xxxxx.xxx
Mass Flow (t/h) xxxx.xxx xxxx.xxx xxxx.xxx
Standard Flow I @ 15.56°C (Sm3/h) xxxxx.xxx xxxxx.xxx xxxxx.xxx
Standard Flow II @ 15.56°C (MMSCFD) xxxx.xxx xxxx.xxx xxxx.xxx
Energy Flow (GJ/h) xxxxxx.xxx xxxxxx.xxx xxxxxx.xxx
CUMULATIVE TOTALS
Gross Volume (m3) xxxxxxxxxx.x xxxxxxxxxx.x
Mass (t) xxxxxxxxxx.x xxxxxxxxxx.x
Standard Volume I @ 15.56°C (Sm3) xxxxxxxxxx.x xxxxxxxxxx.x
Standard Volume II @ 15.56°C (MMSCF) xxxxxxxxxx.x xxxxxxxxxx.x
Energy (GJ) xxxxxxxxxx.x xxxxxxxxxx.x
GC COMPOSITION IN-USE
Methane (mol %) xxx.xxxxx xxx.xxxxx
Ethane (mol %) xxx.xxxxx xxx.xxxxx
Propane (mol %) xxx.xxxxx xxx.xxxxx
i-Butane (mol %) xxx.xxxxx xxx.xxxxx
n-Butane (mol %) xxx.xxxxx xxx.xxxxx
i-Pentane (mol %) xxx.xxxxx xxx.xxxxx
n-Pentane (mol %) xxx.xxxxx xxx.xxxxx
Hexane (mol %) xxx.xxxxx xxx.xxxxx
Heptane (mol %) xxx.xxxxx xxx.xxxxx
Octane (mol %) xxx.xxxxx xxx.xxxxx
Nonane (mol %) xxx.xxxxx xxx.xxxxx
Decane (mol %) xxx.xxxxx xxx.xxxxx
Nitrogen (mol %) xxx.xxxxx xxx.xxxxx
Carbon Dioxide (mol %) xxx.xxxxx xxx.xxxxx
H2S (mol %) xxx.xxxxx xxx.xxxxx
Total (mol %) xxx.xxxxx xxx.xxxxx
Operator Sign: ____________________________________________________ Date: _______________________________________

Engineer Sign: _____________________________________________________Date: _______________________________________

10.5.4. Hourly Report
HOURLY REPORT
LOCATION: AAAAAAAAAAAAAAAA REPORT INITIATED: DD/MM/YYYY HH:MM: SS

CV (15.56,15.56) (MJ/Sm3) xxxx.xxx xxxx.xxx
CURRENT FLOW RATES

PREVIOUS HOUR AVERAGE DATA

Meter Temperature (°C) xxx.xxx xxx.xxx xxx.xxx
Meter Pressure (barg) xxx.xxx xxx.xxx xxx.xxx
Meter Density (kg/m3) xxx.xxx xxx.xxx xxx.xxx
Standard Density @ 15.56°C (kg/Sm3) xxx.xxxxxx xxx.xxxxxx xxx.xxxxxx
CV (15.56,15.56) (MJ/kg) xxxx.xxx xxxx.xxx xxxx.xxx
PREVIOUS HOUR TOTAL

Gross Volume (m3) xxxxxxxxxx.x xxxxxxxxxx.x xxxxxxxxxx.x
Mass (t) xxxxxxxxxx.x xxxxxxxxxx.x xxxxxxxxxx.x
Standard Volume I @ 15.56°C (Sm3) xxxxxxxxxx.x xxxxxxxxxx.x xxxxxxxxxx.x
Standard Volume II @ 15.56°C (MMSCF) xxxxxxxxxx.x xxxxxxxxxx.x xxxxxxxxxx.x
Energy (GJ) xxxxxxxxxx.x xxxxxxxxxx.x xxxxxxxxxx.x
CUMULATIVE TOTALS


10.5.5. Daily Report
DAILY REPORT

CURRENT FLOW RATES

PREVIOUS DAY AVERAGE DATA

CV (15.56,15.56) (MJ/kg) xxxx.xxx xxxx.xxx xxxx.xxx
PREVIOUS DAY TOTAL

CUMULATIVE TOTALS


Rev 003 Page 100 of 115
10.5.6. Monthly Report
MONTHLY REPORT

CURRENT FLOW RATES

PREVIOUS MONTH AVERAGE DATA

CV (15.56,15,56) (MJ/kg) xxxx.xxx xxxx.xxx xxxx.xxx
PREVIOUS MONTH TOTAL

CUMULATIVE TOTALS


Rev 003 Page 101 of 115
10.5.7. Yearly Report
Refer Annexure-A: Yearly report format.
10.5.8. Check Comparison Report
CHECK COMPARISION REPORT

START TIME: DD/MM/YYYY HH:MM: SS
STOP TIME: DD/MM/YYYY HH:MM: SS
CURRENT PROCESS DATA Stream 1 Stream 2

CV (15.56,15,56) (MJ/kg) xxxx.xxx xxxx.xxx
COMPARISION AVG. FLOW

RATES
Gross Flow (m3/h) xxxxx.xxx xxxxx.xxx
Mass Flow (t/h) xxxx.xxx xxxx.xxx
Standard Flow I @ 15.56°C (Sm3/h) xxxxx.xxx xxxxx.xxx
Energy Flow (GJ/h) xxxxxx.xxx xxxxxx.xxx
COMPARISION AVG. DATA

CV (15.56,15,56) (MJ/kg) xxxx.xxx xxxx.xxx
COMPARISION TOTAL DEVIATION (%) Acceptable

Gross Volume (m3) xxxxxxx.xx xxxxxxx.xx x.xxxx (%) YES / NO
Mass (t) xxxxxxx.xx xxxxxxx.xx x.xxxx (%) YES / NO
Standard Volume I @ 15.56°C (Sm3) xxxxxxx.xx xxxxxxx.xx x.xxxx (%) YES / NO
Energy (GJ) xxxxxxxx.x xxxxxxxx.x x.xxxx (%) YES / NO
Deviation = (Duty Meter-Check Meter)*100 / Check Meter

Acceptable limits : +/- X.XXXX % (good conditions)
+/- X.XXXX % (poor conditions)
ACCEPTED BY (OPERATOR) : ____________________________________________ DATE : ___________________
ACCEPTED BY (ENGINEER) : ____________________________________________ DATE : ___________________

Rev 003 Page 102 of 115
10.5.9. Maintenance Report
MAINTENANCE REPORT
PREVIOUS MAINTENANCE TOTAL

Gross Volume (m3) xxxxxxx.xx xxxxxxx.xx
Mass (t) xxxxxxx.xx xxxxxxx.xx
Standard Volume I @ 15.56°C (Sm3) xxxxxxx.xx xxxxxxx.xx
Standard Volume II @ 15.56°C (MMSCF) xxxxxxx.xx xxxxxxx.xx
Energy (GJ) xxxxxxxx.x xxxxxxxx.x


Rev 003 Page 103 of 115
10.5.10. Parameter Report
There is a parameter report for duty/standby Meter Run flow computers & MSC. An example is
shown below.
PARAMETER REPORT
DEVICE: DUTY FLOW COMPUTER

CURRENT PROCESS DATA Units Low Scale High Scale Low Limit High Limit Keypad Mode
Meter Temperature (°C) xxx.xxx xxx.xxx xxx.xxx xxx.xxx xxx.xxx AAAAAAA

Meter Pressure (barg) xxx.xxx xxx.xxx xxx.xxx xxx.xxx xxx.xxx AAAAAAA
Meter Density (kg/m3) xxx.xxx xxx.xxx xxx.xxx xxx.xxx xxx.xxx AAAAAAA
Meter K. Factor (pls/m3) xxxxxx xxxxxx xxxxxx xxxxxx xxxxxx AAAAAAA
Meter Factor x.xxxxxx x.xxxxxx x.xxxxxx x.xxxxxx x.xxxxxx AAAAAAA
Gross Flow (m3/h) - - xxxx.xxx xxxx.xxx xxxx.xxx -

Note: The above format is used to log all changeable data within the relevant device.
10.5.11. Chromat Analysis Report

Due to much chromatograph data during a day, a single daily report with each transaction logged
will be provided rather than a separate report for each transaction.
GAS CHROMATOGRAPH X
ANALYSIS REPORT
Date & Time C1 C2 C3 i-C4 n-C4 i-C5 n-C5 C6 C7 C8 C9+ N2 CO2 H2S
DD/MM/YYYY xxx.xxxxx xxx.xxxxx xxx.xxxxx xxx.xxxxx xxx.xxxxx xxx.xxxxx xxx.xxxxx xxx.xxxxx xxx.xxxxx xxx.xxxxx xxx.xxxxx xxx.xxxxx xxx.xxxxx xxx.xxxxx
HH:MM:SS
HH:MM:SS
HH:MM:SS
HH:MM:SS


Rev 003 Page 104 of 115
10.5.12. Active Alarms Report
There is an active alarm report for the system, an example is shown below.
Alarms Report
Page n of n Report Generated DD/MM/YYYY HH:MM:SS
Source Tag Name Alarm Text Date Time
example of typical entry

Stream-1 FC Meter Run A Pressure PIT-117 Low Alarm DD/MM/YYYY HH:MM:SS
Operator Sign: _____________________________________________ Date: _______________________________________

Engineer Sign: ______________________________________________Date: _______________________________________
10.5.13. Daily Alarms Report

The following is an example that contains some of the possible entries that may appear on the each of
the alarm reports. The example shows the daily alarms. The only difference will be the title name.
Daily Alarms Report
Report
Page n of n Generated DD/MM/YYYY HH:MM:SS
Source Tag Name Alarm Text Date Time
example of typical entry

Stream-1 FC Meter Run A Pressure PIT-117 Low Alarm DD/MM/YYYY HH:MM:SS


Rev 003 Page 105 of 115
10.5.14. Daily Events Report
The following is an example that contains some of the possible entries that may appear on the each of
the event reports. The example shows the daily events.
Daily Events Report
Page n of n Period Start DD/MM/YYYY HH:MM:SS

Period End DD/MM/YYYY HH:MM:SS
Report Generated DD/MM/YYYY HH:MM:SS
examples of typical entries
DD/MM/YYYY HH:MM:SS Administrator Process
Users.Administrator
Logged on
DD/MM/YYYYHH:MM:SS Schedule Process
System.Archive
Archive Requested
DD/MM/YYYYHH:MM:SS System
System.Archive
Archive Request Successful
10.5.15. Daily Quality Report

Refer Annexure-B: Daily Quality Report
10.5.16. Daily Quality Report

Refer Annexure-C: Daily Quantity Report

Rev 003 Page 106 of 115
10.6. Communication To ICSS
The communication between ICSS and Metering System will be over Fible Optic Cable (Provided by
Others). Ethernet to Fibre optic converter, Patch chords and Fibre Optic Patch Panel are provided in
Metering Cabinet. The Fiber optic cable (Provided by Others) to be connected in Fibre Optic Patch
Panels by others.
Total two Modbus TCP/IP communication links are provided from MSCs (Single Link from each MSC)
to ICSS. The ICSS will act as ‘Master’ device and the MSCs will act as ‘Slave’ device.
In idle condition (one MSC is Duty and other MSC is Standby), both the links will remain active. In case
of one of the MSC failure, the other MSC will become Duty. Each link will provide Duty Status of the
MSC (i.e.: MSC-A is Duty or MSC-B is Duty). ICSS to verify healthy communication link/s and initiate
the communication with the Duty MSC.
ICSS system will have data as per submitted software database exchange table (Modbus register)
document, document no. MGP1-BOC1888PO001-C99-0001, all the data are given as read only
parameters to the ICSS system.
Below table describes the communication details of the MSCs:
Description MSC
Communication Link Ethernet (1 nos.) From MSC-A
Ethernet (1 nos.) From MSC-B
IP Address MSC-A : TBA by ICSS
MSC-B : TBA by ICSS
Protocol Modbus TCP
Mode Slave

Comments:

Rev 003 Page 107 of 115
11. Fire Alarm Control Panel (FACP)
11.1. Fire & Gas Detectors
Different type of gas detectors, flame detectors are used and connected with FACP panel details are
as per below table.
Type of Detector Service Tag
Flammable Gas Detection GD-441
Flammable Gas
Detector
Toxic Gas Detection TGD-441
Toxic Gas Detector
Flame Detection FD-441
Fire / Flame Detector
Heat Detector Heat Detection HD-441
Smoke Detection SD-441
Optical Smoke
Detector
Hydrogen Gas Detector Hydrogen (H2) Detector HGD-441

Rev 003 Page 108 of 115
11.2. Fire & Gas PLC
This Section describes the Fire & Gas PLC functionality. The Fire and Gas PLC provides digital I/O’s
processing, Analog I/P processing, and Alarm Annunciation as per the Cause-and-Effect diagram.
For details regarding control and operation of different instrument connected to FACP PLC refer
to the cause-and-effect diagram client document no. 'MGP1-BOC1888PO001-C14-0001, Alderley
document no. 33013M-01-P-1633-01.
11.2.1 PLC Digital Input Signals

Temperature Switch
Total 1 nos. of Temperature switch with individual Digital inputs connecting to FACP PLC, is
installed for monitoring Temperature in Equipment room.
3
3 Pressure Switch
Total 1 nos. of Pressure switch with individual Digital inputs connecting to FACP PLC, is installed
for monitoring Pressure in Equipment room.
Door Limit Switch
Total 3 nos. of door switch with individual Digital inputs connecting to FACP PLC, are installed
for monitoring Airlock in Equipment room, battery room and airlock room.
Optical Smoke Detector
Total 3 nos. of Smoke detector with individual Digitals inputs connecting to FACP PLC, are
installed in Equipment room, battery room and airlock room.
Flame detector
Total 3 nos. of Flame detector with individual Digital inputs connecting to FACP PLC, are installed
in 1 in Equipment room, 1 in battery room, 1 in airlock room.
Heat Detector
1 nos of Heat detector with Digital input connecting to FACP PLC installed in battery room.
Manual Call Point
2 nos of digital input individually are connected to FACP PLC, from manual call point instrument.
1-manual call point installed in CCR and other at metering skid area.

Rev 003 Page 109 of 115
11.2.2 PLC Digital Outputs
Air Conditioning Unit
Total 4 Air Conditioning Unit are controlled by FACP PLC with individual digital Outputs. 2 AC
units (1+1 standby) are in Equipment room and 2 AC units (1+1 Standby) are in Battery room.
For control & operation of Air conditioning units Please refer to the cause-and-effect diagram
client document no. 'MGP1-BOC1888PO001-C14-0001, Alderley document no. 33013M-01-P-
1633-01.
Fresh Air Fan
Total 2 Fresh Air Fan installed in Equipment room controlled by FACP PLC with individual Digital
outputs.
Fire Damper
There is total 4 nos of Fire dampers controlled by FACP PLC with individual digital outputs. (2
fresh air fire damper in Equipment room and 2 Exhaust Fire damper in Battery room).
Exhaust Fan
Total 2 nos of Exhaust fan installed in battery room are controlled by FACP PLC with individual
Digital outputs.
Sounder / Audible alarm
Total 2 nos of Sounder (1 installed in CCR & other in metering Skid area) are controlled by FACP
PLC with individual digital outputs.
Beacon / Visual alarm
Total 2 nos of Beacon (1 installed in CCR & other in metering Skid area) are controlled by FACP
PLC with individual digital outputs.
Confirmed fire in skid area
1 nos of Digital output generated from FACP PLC based on flame detectors in metering skid area
and it is hardwired to ICSS for confirmation of fire in metering skid area.
Confirmed Gas leak in Skid area
1 nos of Digital output generated from FACP PLC based on toxic gas detector in metering skid
area and it is hardwired to ICSS for confirmation of gas leak in metering skid area.
Emergency Exit lights
Total 3 nos of Emergency Exit lights are controlled by FACP with individual digital outputs.

Rev 003 Page 110 of 115
11.2.3 PLC Analog Inputs
Hydrogen Gas Detectors
There is 1 nos of hydrogen gas detector installed in battery room and connected to FACP PLC as
analog input for monitoring and to take corrective action as per C&E chart.
Fire Gas Detectors
There are total 3 nos of fire gas detector installed in (2 in metering skid are and 1 in GC shelter
area) are connected to FACP PLC as analog input for monitoring and to take corrective action as
per C&E chart.
3 Flammable Gas Detectors

3 There are total 3 nos of flammable gas detectors (1 in Equipment room + 1 in Airlock room + 1 in
Battery room) connected to FACP PLC as analog input.
Toxic Gas Detectors
There is total 6 nos of Toxic gas detectors installed. 1 in Equipment room, 1 In airlock room, 1 in
battery room, 2 nos of detector in Metering skid area & 1 nos of detector is installed at GC shelter
area.

Rev 003 Page 111 of 115
11.3. FACP Communication to DCS / ICSS
Fire alarm control Panel is connected to DCS / ICSS system via fibre optic media.
FO patch cable from FACP panel will be connected to redundant FO patch panel available in CP000-
MET-UCP-001 Sweet gas custody transfer metering panel. There after FO cable (supplied by others)
will connect the system to DCS/ ICSS system.
For more information, please refer to CONTROL SYSTEM ARCHITECTURE DRAWING - CPF1 GAS METERING
SKID Document no. MGP1-BOC1888PO001-C15-0001
Details of Modbus register signals available as per FACP Modbus list documentation.
Additionally, two Digital output signals “confirm fire in metering skid area” and “confirm gas leak in metering
skid area” are Hard wired from FACP panel to ICSS.
11.4. UPS System Design and calculations

Please refer to the following documents for UPS system design, datasheet, and calculations.
CLIENT DOC. NO. DESCRIPTION AFZE DOC. NO.

MGP1-BOC1888PO001-E09- UPS SYSTEM WITH BATTERY DATASHEET - CPF1 GAS 33013M-01-P-0917-11
0014 METERING SKID
MGP1-BOC1888PO001-F14- CONTAINERIZED CONTROL CUBICLE UPS SIZING 33013M-01-E-0933-01
0004 CALCULATION - CPF1 GAS METERING SKID

Rev 003 Page 112 of 115
ANNEXTURE-A
YEARLY REPORT FORMAT

Rev 003 Page 113 of 115
CPF-1 GAS METERING SKID
SWEET GAS CUSTODY TRANSFER METERING
24-HOUR DAILY QUALITY REPORT
LOCATION: CPF-1 GAS METERING SYSTEM REPORT INITIATE DATE/TIME: 21/05/2024 00:02:52
MSC: S01_MSC_A
---- Stream-1 Stream-1 Stream-1 Stream-1 Stream-2 Stream-2 Stream-2 Stream-2

Hour Gross vol Standard Vol1 Standard Vol2 Mass Gross vol Standard Vol1 Standard Vol2 Mass
---- (m³) (Sm³) (MMSCF) (Tonne) (m³) (Sm³) (MMSCF) (Tonne)
1:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
2:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
3:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
4:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
5:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
6:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
7:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
8:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
9:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
10:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
11:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
12:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
13:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
14:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
15:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
16:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
17:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
18:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
19:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
20:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
21:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
22:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
23:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
0:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Operator Sign:__________________________________________ Date:__________________________________________ Engineer Sign:__________________________________________ Date:__________________________________________

ANNEXTURE-B
DAILY QUALITYSSS REPORT FORMAT

Rev 003 Page 114 of 115
24-HOUR DAILY QUANTITY REPORT
LOCATION: CPF-1 GAS METERING SYSTEM REPORT INITIATE DAsTE/TIME: 21/05/2024 00:02:32
MSC: S01_MSC_A
---- Stream-1 Stream-1 Stream-1 Stream-1 Stream-1 Stream-2 Stream-2 Stream-2 Stream-2 Stream-2
Hour Meter Temp. Meter Press. Meter Density Std.Density CV(15.56,15.56) Meter Temp. Meter Press. Meter Density Std.Density CV(15.56,15.56)
---- (°C) (barg) (Kg/m³) (Kg/Sm³) (Mj/Kg) (°C) (barg) (Kg/m³) (Kg/Sm³) (Mj/Kg)
1:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
2:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
3:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
4:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
5:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
6:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
7:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
8:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
9:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
10:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
11:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
12:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
13:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
14:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
15:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
16:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
17:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
18:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
19:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
20:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
21:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
22:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
23:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000
0:00 0.000 0.000 0.000 0.000000 0.000 0.000 0.000 0.000 0.000000 0.000

ANNEXTURE-C
DAILY QUANTITY REPORT FORMAT

Rev 003 Page 115 of 115
24-HOUR DAILY QUALITY REPORT
LOCATION: CPF-1 GAS METERING SYSTEM REPORT INITIATE DATE/TIME: 21/05/2024 00:02:52
MSC: S01_MSC_A
---- Stream-1 Stream-1 Stream-1 Stream-1 Stream-2 Stream-2 Stream-2 Stream-2

Hour Gross vol Standard Vol1 Standard Vol2 Mass Gross vol Standard Vol1 Standard Vol2 Mass
---- (m³) (Sm³) (MMSCF) (Tonne) (m³) (Sm³) (MMSCF) (Tonne)
1:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
2:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
3:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
4:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
5:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
6:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
7:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
8:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
9:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
10:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
11:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
12:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
13:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
14:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
15:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
16:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
17:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
18:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
19:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
20:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
21:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
22:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
23:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
0:00 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

MGP1 Boc1888po001 C19 0001 - 003

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Majnoon Oil Field EPCM Services Project

COMMENTS RESPONSE SHEET (CRS)

Document No. : MGP1-BOC1888PO001-C19-0001

1 Page No. 24 002 Noted & Incorporated

GC-434 Diagnostics link is connected to Ethernet Switch-1 & GC-454 Diagnostics

Page No 30 002 Noted & Updated the Tag Numbers

Document No. : MGP1-BOC1888PO001-C19-0001

5 Page No 31 002 Noted & Incorporated

6 Page No 35 002 Noted, RGC 3000 will be provided on both MSC.

Document No. : MGP1-BOC1888PO001-C19-0001

9 Page no 71 002 Noted & Incorporated

11 Page no 75 002 Noted & Incorporated

12 Page no 81 002 Noted & Incorporated(Internal Signals there are no tags)

14 Page no 108 002 Noted & Incorporated

Document No. : MGP1-BOC1888PO001-C19-0001

Prepared By: Piyush Parmar

Approved By: Amit Chauhan

VENDOR DOCUMENT REVIEW SHEET

Purchase Order Number: BOC-PO-1888-001

Purchase Order Title: BOC-1888- GAS METERING SKID FOR CPF1

Suppliers Name: ALDERLEY

Suppliers Reference Number and Revision: No. Rev.

Supplier (Checked By) Amit Chauhan

Supplier (Approved By) with Date Renji Mathew

MGP1 BOC1888PO001 C19 0001 001 003 IFA

Review Code and Status

PROJECT: Majnoon Oil Field EPCM Services

Document Number: MGP1-BOC1888PO001-C19-0001 Alderley Document Number: 33013M-01-C-0940-01

Document Number: MGP1-BOC1888PO001-C19-0001 Alderley Document Number: 33013M-01-C-0940-01

Document Number: MGP1-BOC1888PO001-C19-0001 Alderley Document Number: 33013M-01-C-0940-01

Document Number: MGP1-BOC1888PO001-C19-0001 Alderley Document Number: 33013M-01-C-0940-01

Document Number: MGP1-BOC1888PO001-C19-0001 Alderley Document Number: 33013M-01-C-0940-01

Document Number: MGP1-BOC1888PO001-C19-0001 Alderley Document Number: 33013M-01-C-0940-01

Document Number: MGP1-BOC1888PO001-C19-0001 Alderley Document Number: 33013M-01-C-0940-01

1.1.1. Stage 1 – Fundamental Principles and Operation

1.1.2. Stage 2 – Detailed Design

1.1.3. Stage 3 – Final Details

Document Number: MGP1-BOC1888PO001-C19-0001 Alderley Document Number: 33013M-01-C-0940-01

1.2. Description of Section Test Procedure

Functionality Tested Evidence: Section XX

Basra Oil Company (BOC) /

1.2.1. How will the Functionality Testing Box be used?

Document Number: MGP1-BOC1888PO001-C19-0001 Alderley Document Number: 33013M-01-C-0940-01

Acceptance Test Manual

Document Number: MGP1-BOC1888PO001-C19-0001 Alderley Document Number: 33013M-01-C-0940-01

1. Verification of Metering Control Panel Functionality

The diagram below illustrates the process:

1.3.2. Metering Control Panel Test Sequence

Metering Control Panel

Verification of Simulated Metering Skid

Document Number: MGP1-BOC1888PO001-C19-0001 Alderley Document Number: 33013M-01-C-0940-01

1.3.4. Completion of Factory Acceptance Test (FAT)

1.3.5. System Query Reports

Document Number: MGP1-BOC1888PO001-C19-0001 Alderley Document Number: 33013M-01-C-0940-01

Document Number: MGP1-BOC1888PO001-C19-0001 Alderley Document Number: 33013M-01-C-0940-01

Document Number: MGP1-BOC1888PO001-C19-0001 Alderley Document Number: 33013M-01-C-0940-01

2.1. Operating Conditions

2.1.1. Gas Operating Conditions

Design Temperature -20 - 90.3 o