JASA KONSULTASI

PERENCANAAN PEKERJAAN
INSTRUMENTASI TANKI STORAGE
CPO DI PERAK

TERMINAL AUTOMATION SYSTEM SPECIFICATION

Contract No : HK.0502/296.1/P.III- Page 1 of 15

Doc. No : PEL-TP-00-INS-SP-004
2016

EMPLOYER : PT. PELABUHAN INDONESIA III (PERSERO)

JASA KONSULTASI PERENCANAAN PEKERJAAN

PROJECT TITLE :
INSTRUMENTASI TANKI STORAGE CPO DI PERAK

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

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

REV PRP'D CHK'D APV'D

DATE DESCRIPTION PELINDO III
. OSTRADA INDONESIA
 JASA KONSULTASI
PERENCANAAN PEKERJAAN
INSTRUMENTASI TANKI STORAGE
CPO DI PERAK

TERMINAL AUTOMATION SYSTEM SPECIFICATION

Contract No : HK.0502/296.1/P.III- Page 2 of 15

Doc. No : PEL-TP-00-INS-SP-004
2016

REVISION HISTORICAL SHEET

Rev. Date Page Description

0 08/08/2016 All New doc

 JASA KONSULTASI
PERENCANAAN PEKERJAAN
INSTRUMENTASI TANKI STORAGE
CPO DI PERAK

TERMINAL AUTOMATION SYSTEM SPECIFICATION

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Doc. No : PEL-TP-00-INS-SP-004
2016

TABLE OF CONTENT

1. INTRODUCTION.................................................................................................................. 4
1.1 Project Overview..................................................................................................................4
1.2 Scope................................................................................................................................... 4
2. DEFINITION......................................................................................................................... 5
3. CODE, STANDARD & REFERENCE...................................................................................5
4. TERMINAL AUTOMATION SYSTEM GENERAL DESIGN..................................................6
4.1 General................................................................................................................................ 6
4.2 Description TAS................................................................................................................... 8
5. INSPECTION TESTING AND PRE COMMISIONING........................................................12
5.1 General.............................................................................................................................. 12
5.2 Factory Acceptance Test (FAT)..........................................................................................12
5.3. Site Acceptance Test (SAT)...............................................................................................13
6. MARKING AND TAGGING.................................................................................................13
7. DOCUMENTATION............................................................................................................ 14
7.1 Bid Documentation............................................................................................................. 14
7.2 Design Documentation.......................................................................................................14
7.3 Final Documentation........................................................................................................... 14
8. WARRANTY....................................................................................................................... 15
9. TRAINING.......................................................................................................................... 16
 JASA KONSULTASI
PERENCANAAN PEKERJAAN
INSTRUMENTASI TANKI STORAGE
CPO DI PERAK

TERMINAL AUTOMATION SYSTEM SPECIFICATION

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Doc. No : PEL-TP-00-INS-SP-004
2016

1 INTRODUCTION

1.1 Project Overview

Currently PT. Pelindo III (Persero) is managing development of CPO Storage Tank in
Nilam Tengah Terminal at Tanjung Perak Port, Surabaya.

This project is expected to fulfill goals and objectives, which is to serve CPO supply.
The CPO come from Floating Storage or tanker at Tanjung Perak Port which will be
streamed through CPO pipeline transmission to fulfill the need of Crude Palm Oil at
Nilam Tengah Terminal.

This development of Storage Tank will be equipped with Integrated Monitoring

System for CPO management which utilize Terminal Automation System (TAS).The
TA act as controller according to its operation and safety philosophy.

1.2 Scope

This specification covers minimum requirements of the Terminal Automation System

TAS.

CONTRACTOR shall be responsible for the complete TAS system up until full and
final acceptance of the installed and tested system.

CONTRACTOR shall be responsible to design, manufacture, supply and configure

the system, including provision of capability of installing new facility.

This specification defines the minimum requirements for the design standards and
engineering practices to be used on the instrumentations systems and control
equipments. Any commissions or details in this specification shall not be relieves the
Contractor or Supplier of the obligation to furnish instrumentation that is complete
and fully operational.
 JASA KONSULTASI
PERENCANAAN PEKERJAAN
INSTRUMENTASI TANKI STORAGE
CPO DI PERAK

TERMINAL AUTOMATION SYSTEM SPECIFICATION

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Doc. No : PEL-TP-00-INS-SP-004
2016

2 DEFINITION

PROJECT  Jasa Konsultasi Perencanaan Pekerjaan Instrumentasi

Tanki Storage CPO di Perak.
COMPANY  PT Pelindo III (Persero) as an owner of the PROJECT
CONSULTANT  PT Ostrada Indonesia appointed by COMPANY as their
Engineering Consultant.
CONTRACTOR  PT Weltes Energi Nusantara
VENDOR/SUPPLIER  A company providing specific materials or services
required for the construction of the Facility

3 CODE, STANDARD & REFERENCE

This specification document based to the last edition code and standard as shown
below:

 API RP 551 : Process Measurement Instrumentation

 API RP 554 : Process Instrumentation and Control
 BS 6121 : Cable Glands
 BS 6755 : Test of Valves
 IEC 60228 : Conductors of Insulated Cables
 IEC 61000-4 : Electromagnetic Compatibility - Testing & Measurement
 IEC 60348 : Safety Requirements for Electronic Measuring
Apparatus
 IEC 60529 : Classification of Degree of Protection Provided by
Enclosures – Ingress Protection (IP) Code
 IEC 60584 : Thermocouple
 IEC 60654-1 : Industrial Process Measurement and Control
Equipment - Operating Conditions - Part 1: Climatic
conditions
 IEC 60751 : Industrial Platinum Resistance Thermometer Sensors-
 JASA KONSULTASI
PERENCANAAN PEKERJAAN
INSTRUMENTASI TANKI STORAGE
CPO DI PERAK

TERMINAL AUTOMATION SYSTEM SPECIFICATION

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2016

RTD
 IEC 60770 : Transmitters for use in industrial-process control system
 IEC 61331 : Fire Resistant Cable Test
 IEEE-802.3 : Local Area Network.
 IEEESTD.830 : Guide to Software Requirement Specifications.
 IEEESTD.1012 : Standard for Software Verification and Validation Plans.
 IEEESTD.1016 : Recommended Practice for Software Design Descriptions
 IEEE472-74 : Guide for Surge With stand Capacity (SWC) Test.
 ISA5.1 : Instrumentation Symbols and Identification
 ISA S 5.2 : Binary logic diagram for process operations
 ISA 5.3 : Graphic Symbols for Distributed Controls

4 TERMINAL AUTOMATION SYSTEM GENERAL DESIGN

4.1 General

This specification defines the minimum requirements of Terminal Automation System

(TAS) need for reliable, effective and optimum control & monitoring of Terminal
operations.

Requirement Material refer to Doc. No. PEL-TP-00-INS-MT-001 Instrument

Material Take Off.

In order to distribute CPO products and to keep track of the material movement
computerized Terminal Automation Systems is needed. The Terminal Automation
System, hereafter called the system or "TAS" shall be capable of terminal wide
automation. The architecture of the system shall accommodate both functional and
geographical distribution of the hardware, software, and database over the terminal
while allowing system wide access to the distributed data. The TAS shall utilize a
modular & scalable architecture to permit wide range of system configurations and
facilitate system flexibility and expandability. It shall include real-time monitoring
 JASA KONSULTASI
PERENCANAAN PEKERJAAN
INSTRUMENTASI TANKI STORAGE
CPO DI PERAK

TERMINAL AUTOMATION SYSTEM SPECIFICATION

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display & control of the field instrumentation level, supervisory control, access
control, terminal security, transaction processing and product inventory tracking at
terminal level. The Terminal Automation System software (latest version) shall be
governed by the operating system running in a real time mode and shall be able to
meet all functional requirements as specified by owner. This customized system shall
be working simulated with the instrumentation systems, which in turn monitors &
controls the entire terminal.

The system architecture shall be open, providing data movement horizontally and
vertically throughout the operations structure. The field communication shall be
preferably through Ethernet 10/100 Mbps or RS-232C or RS485 communications
interface for data transmission to DCS/ PLC. The system shall be based on reputed
and approved makes of Distribution Control System ( TAS Requirement ) and
Programmable Logic Controllers.

The basic function of this system shall be as follows.

• Controlling and monitoring the product movement.

• HMI Display shall be with real time data updates.
• Controlling the unloading system
• Controlling the truck filling system
• Emergency Shut Down
• Data acquisition and instruments controlling various instrumentation
loops.
• Generating history profile
• Reporting and displays

4.2 Description TAS

Terminal Automation System (TAS) on the installation depot or terminal Transit is an

integrated system that includes an outline of facilities, facilities include on Tank’s
Receiving CPO and Distribution Facilities

Terminal Management System (TMS)

 JASA KONSULTASI
PERENCANAAN PEKERJAAN
INSTRUMENTASI TANKI STORAGE
CPO DI PERAK

TERMINAL AUTOMATION SYSTEM SPECIFICATION

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2016

TMS is an integrated terminal management system at MES level. It can send

commands to the control system via the interface with the process control system,
and also transmit necessary data to the ERP (Enterprise Resource Planning)
system. Manufacturing Execution System (MES) Level makes it easier to stay in
control of operations such as unloading, recipe management, sampling, etc., as well
as to monitor critical information including volumes, temperature and other vital
conditions. In short, keeps track of all important aspects of work order deployment,
and is able to interact directly with both PCS, SIS and ERP systems.

TMS is mainly responsible for the operations and management of the entire
production and business processes at the terminal. With integrated management
throughout all business processes, besides being able to enhance the operation
efficiency at the terminal, it is also able to standardize and improve companies
management effectiveness.

With a standard database as its core, TMS provides data display and output in
various forms of data sheets and graphs.

Process Control System

Process Control system is a unified platform for sequential control, process control,
electrical control and safety control.

Performs data acquisition, control and management of production control, and

transmits and receives process variables from the control center. Authorized staff at
the plant may perform monitoring, control, scheduling and management over the
entire plant through the control center.

Its main features include :

 Data acquisition: to collect, display, record and provide alarms on process

parameters, fire control, electrics, cathodic protection and equipment
condition (failure and analysis of the pumps and instruments) as well as other
related data
 JASA KONSULTASI
PERENCANAAN PEKERJAAN
INSTRUMENTASI TANKI STORAGE
CPO DI PERAK

TERMINAL AUTOMATION SYSTEM SPECIFICATION

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 Control: real-time control of equipment (valves/ pumps)

 Display: running status, operating instructions, dynamic trends, historical

trends, simulative process flow diagrams

 Authorization and user management

 Alarm report processing: display of alarms and events and printing of reports

 Database: real-time data collection and establishment of historical and real-

time databases of the control system

 Programming and configuration: programming, configuration and data editing

of the control system

 Communication : communication among the measuring system, automation

system and other subsystems

Safety System

Safety control at the terminal involves equipment safety, personal safety and
environmental safety, and thus is the top priority in the terminal operation. TAS
provides solutions which standard, which can effectively realize safety control of the
entire plant including the tank area, pump area and filling station area.

Fire & Gas System includes :

 Fire-area control philosophy

 Automatic control, interlocking control and monitoring of the fire pumps,

electric valves and firefighting control

 Automatic water replenishment of the fire water tank

 High-pressure stability automation system

 Heat, smoke and flame detectors, on-site manual fire call point, combustible
gas signal detection acquisition, monitoring and alarm system
 JASA KONSULTASI
PERENCANAAN PEKERJAAN
INSTRUMENTASI TANKI STORAGE
CPO DI PERAK

TERMINAL AUTOMATION SYSTEM SPECIFICATION

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 Alarm signal to the industrial CCTV system

 Signals interlock to the emergency evacuation system

Terminal Loading System

The terminal loading system is applied in the Tank receiving operations at the
terminal to improve the accuracy of product receipt or delivery, and lowers costs and
improves efficiency by automating. At the same time, it helps to avoid accidents
caused by static electricity, manual measurement, and abnormal loss of product.
Meanwhile, it also provides accurate data to the upper ERP management system to
significantly improve the management and macro-control capability of the tank.

 Operator authorization management

 Driver and vehicle authorization management

 Fill in, submit and process bills of materials

 Loading preparation, execution and completion of the entire management

process

 Acquisition and use of flow and weight signals

 Intelligent control and interlocking protection of pumps and valves

 Dynamic screen display of loading process,

 Safety protection systems, static electric grounding as well as recovery

systems

 Reports, billing and invoice printing

 Data archiving and database management

Motor Control System

Design motor control provides a complete set of intelligent motor control centers,
offering advanced and reliable electrical control for the Transfer pump area.
 JASA KONSULTASI
PERENCANAAN PEKERJAAN
INSTRUMENTASI TANKI STORAGE
CPO DI PERAK

TERMINAL AUTOMATION SYSTEM SPECIFICATION

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Communication System

By adopting a completely open architecture and supporting standard communication

interfaces and protocols, TAS allows easy and convenient data sharing within an
enterprise. The system can communicate with third-party equipment and ERP
system by means of serial communication, ModBus, DeviceNet, ControlNet,
EtherNet/IP, OPC, etc.

5 INSPECTION TESTING AND PRE COMMISIONING

5.1 General

In addition to the inspection and testing specified in the accompanying requisition

documents, CONTRACTOR shall also comply with the minimum requirements
specified herein.

CONTRACTOR shall provide to CLIENT, not less than six (6) weeks prior to the date
of commencement of the tests, a detailed schedule of the tests and sample test
record forms for approval. The tests shall not be undertaken until the test schedule
and test forms are approved by CLIENT.

An operating and maintenance manual and final certified copy of “As-Built” drawings
shall be provided for the Inspector’s exclusive use during final works testing and
inspection.

5.2 Factory Acceptance Test (FAT)

Test shall be witnessed by CLIENT.

Testing shall consist of a full functional simulation test of Functional TAS control and
annunciation logic utilizing hard-wired simulator racks, including the following as a
minimum:

 dry contact switches for discrete input simulation,

 pilot lights for discrete output monitoring,

 JASA KONSULTASI
PERENCANAAN PEKERJAAN
INSTRUMENTASI TANKI STORAGE
CPO DI PERAK

TERMINAL AUTOMATION SYSTEM SPECIFICATION

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 4-20 mA generators for transmitter simulator,

 digital displays for analog output monitoring,

Functional testing of the TAS system shall include all components (all pieces of
equipment) of the system being furnished by the CONTRACTOR, including
Workstation, Hot Stand-by and Man Machine Interface (MMI). Functional testing
shall be accomplished via hard wired data links among the various system
components, mirroring the actual field communications configuration as closely as
possible.

The MMI system graphic display screens shall be utilized to verify that annunciation,
operator interaction, reporting, and data logging functions are functional and correct.

These tests shall be fully documented.

5.3 Site Acceptance Test (SAT)

CONTRACTOR shall provide complete details system of installation and a detailed

site acceptance test procedure. CONTRACTOR shall certify the installation of the
TAS equipment/system at the constructed site.

CONTRACTOR must validate the TAS system after commissioning. This shall
include pre-start-up and system integration.

The validation shall be witnessed by the CLIENT. The validation procedure must be
submitted to CLIENT for approval four (4) weeks prior to commencement.

6 MARKING AND TAGGING

Nameplates and tags are required for each panel and other component that
identified on the project drawings and documents. CONTRACTOR shall mark all tag
numbers on Contractor’s approval documents.

Nameplate and tags shall be die-stamped stainless steel plates attached at an easily
accessible point on the panel. Panels shall have a nameplate and/or tag permanently
affixed to the device prior to shipping.
 JASA KONSULTASI
PERENCANAAN PEKERJAAN
INSTRUMENTASI TANKI STORAGE
CPO DI PERAK

TERMINAL AUTOMATION SYSTEM SPECIFICATION

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Nameplates and tags shall include information describing the serial number, function,
set point, ranges, and other technical information related to the item.

7 DOCUMENTATION

7.1 Bid Documentation

CONTRACTOR shall submit drawings the proposed designs, complete with a full
description and component identification.

7.2 Design Documentation

Design documentation shall be supplied in accordance with project documents.

This shall include, as a minimum, the following:

 System description,

 Mean time between failure figures for electrical/electronic equipment,

 General arrangement and cross sectional drawings, complete with parts list,
materials of construction and description, and system description,

 Price list of recommended commissioning spares,

 Price list of recommended spare parts for two years operation,

 Price list of special tools,

 Itemized list of Contractor’s deviation from Specification,

 Weight, and

 Delivery.

7.3 Final Documentation

A Manufacturing Record Book shall be complied concurrently with fabrication such

that a full record of the fabrication, materials, inspection and testing is available.
 JASA KONSULTASI
PERENCANAAN PEKERJAAN
INSTRUMENTASI TANKI STORAGE
CPO DI PERAK

TERMINAL AUTOMATION SYSTEM SPECIFICATION

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All items in the Manufacturing Record Book shall be numbered. Contents shall
include, but not be limited to, the following:

 Front cover sheet

 I/O List

 System and Component Power Consumption Calculation

 Detailed specifications and Manuals of the offered hardware and software

 Operating Instructions

 Drawings which include Architecture Diagrams, Terminal Descriptions, Panel

Marshaling Wiring and PLC/DCS Input/Output

 Hard copy of the PLC/DCS Program

 TAS Graphics

 Spare Part List

Operating Manuals shall be assembled into an A4 size post binder and shall contain:

 Operating and maintenance procedures,

 All “As-Built” drawings and documents,

 Schedules of commissioning and operating spare parts for two years

services, and

 Programming data and software.

Documentation to include both hard copy and electronic copies of drawings, data
sheets, configuration and programming software, operating and maintenance
procedures.
 JASA KONSULTASI
PERENCANAAN PEKERJAAN
INSTRUMENTASI TANKI STORAGE
CPO DI PERAK

TERMINAL AUTOMATION SYSTEM SPECIFICATION

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8 WARRANTY

Warranty provisions are specified in the Standard Terms and Conditions attached to
the Bid Request and apply to CONTRACTOR and subcontractors and/or suppliers. If
modified warranty terms are agreed to between CLIENT and CONTRACTOR, these
modified provisions will be incorporated in the Purchase Order.

9 TRAINING

The CONTRACTOR shall provide at least one-week training session to operations

personnel at the Contractor’s facility after Site Acceptance Testing is complete.