1. Introduction
This document specifies the Operational Technology (OT) requirements for the PED Coal Automation System (PED CAS). It must be read as an extension of the Conceptual Design Document [1]. The diagram below provides the context, within the PED CAS, for the OT requirements specified within this document.
Figure 1 - PED Coal Automation Systems Overview
2. Supporting Clauses
Scope
The scope of this document covers the OT requirements to support the overall architecture and design of the solution proposed for the PED Coal Automation System in [1].
Purpose
This document aims to provide a set of minimum OT requirements to be delivered by the Contractor.
Normative/Informative References
[1] Conceptual_Design_v1.1
[2] Data_Architecture_Design_v1.3
[3] Eskom Execute Primary Energy Operations – Proposed Coal Value Chain PCM_v1.0
Informative
Definitions
Term
Definition
Collops
The Collops system is an MS Excel front end over an Oracle database which houses all the coal deliveries from the various suppliers, the mode of delivery, volume of coal burnt, total system stock and stock days per power station
Delivered/ DEL
Supplier/Mine-managed transporters
Eskom-managed transporters
Load cell
A force transducer which, after taking into account the effects of the acceleration of gravity and air buoyancy at the location of its use, measures mass by converting the measured quantity (mass) into another measured quantity. Note: Load cells equipped with electronics, including an amplifier, an analogue-to-digital converter and a data processing device are called digital load cells (SANS 1649:2014)
Project
Terminal
A digital device that has one or more keys to operate the instrument, and a display to show the weighing results transmitted via the digital interface of a weighing module or an analogue data processing device (SANS 1649:2014)
Type approval
The decision (made by the NRCS) that a type of measuring instrument complies with the relevant requirements of this Act and is suitable for use for a prescribed purpose in such a way that it is expected to provide reliable measurement results over a defined period of time
Weighing instrument
A measuring instrument that serves to determine the mass of a body using the action of gravity on such a body (SANS 1649:2014)
Abbreviations and acronyms
Abbreviation and Acronym
CCTV
GA
NVR
SLA
General Requirements
Overview
a) The scope of work includes the detail design, engineering drawings, procurement, manufacture, quality control and assurance, supply and delivery, installation, commissioning, testing, handover as well as maintenance of all materials and equipment during the guarantee period of all works required to realise a fully functional PED CAS.
b) All cabling, racking, trenching, plinths, foundations, etc. required to realise the complete PED CAS are designed and installed by the Contractor.
c) The Contractor purchases all software and design packages as well as their associated licenses required to fulfil the requirements of the complete PED CAS. All licenses associated with software installed on OT Plant must be perpetual.
d) The Contractor purchases all hardware, computers, field programmers and associated peripherals required to fulfil the requirements of the complete PED CAS.
e) The Contractor provides for all power supply requirements to ensure that a fully functional PED CAS is realised and delivered.
f) The Contractor complies with the codes and standards listed in section 3.1.3 for all aspects of the works stated herein.
g) All OT designs and interfaces are developed in collaboration with Eskom Group Security, Group IT and Engineering. All designs are required to be signed-off by these stakeholders as well as any other stakeholders the Project Manager deems necessary.
Design Life
a) Based on 474-10592 Generation Plant Engineering Life Cycle Planning/Strategic Report for Control and Instrumentation Equipment for 2015, the expected life of the components below is as follows:
· Programmable Logic Controllers – 12 to 15 years,
· Communication cards installed on weighing equipment – 8 to 12 years
· Networking devices, switches, repeaters, satellite equipment – 3 to 6 years
· Operator consoles inside weighbridge cabins – 3 to 6 years
· Auto-ID scanning devices – 3 to 6 years
· Telematics and safety devices on vehicles – 3 to 6 years
· Video surveillance equipment – 8 to 12 years
b) All other OT components supplied are supported for a minimum of 10 years after Handover.
c) No components are installed that will only be available from 3rd party vendors within 10 years after Handover.
d) The Contractor submits product lifecycle statuses of critical OT components during the Detailed Design Specification to support the requirements in this section.
e) The process used in defining the criticality of OT components is guided by FMECA. The Contractor facilitates this process and submits an FMECA report(s) during the Detailed Design Specification.
Codes and Standards
The following codes and standards are complied with for all design and installation work associated with the PED CAS solution. The latest revisions of all standards listed below apply. All national and international standards are procured by the Contractor.
Standard/Specification
Reference
Automation systems in the process industry – Factory acceptance test (FAT), site acceptance test (SAT), and site integration test (SIT)
IEC 62381
Coal Fired Power Stations Lightning and Small Power Installation Standard
240-55714363
SANS 2001-CC1
SANS 2001-CS1
240-56355815
240-55410927
240-56356396
Environmental Conditions for Process Control Equipment Used at Power Stations Standard
240-56355731
240-131050633
240-49230046
474-10592
32-438
Mass Meters for Coal Measurement in Power Stations Design Standard
240-55864550
240-63236839
240-53114026
Requirements for Control and Power Cables for Power Stations Standard
240-56227443
SANS 60793 Series
240-91190304
SANS 1200 Series
SANS 1200 D
SANS 10100-1
SANS 10162
240-53114248
DRAFT
DRAFT
Capability at Power Stations
Overview
Eskom requires the capability of an Automated Coal Value Chain. The automated system shall provide the user with a "single version of the truth" of the end-to-end movement of coal volumes and coal quality across the Primary Energy Value Chain. The following capability is required at Power Stations to realise the Automated Coal Value Chain:
· Automated Data Logging for Coal Reconciliation and Accounting;
· Un-manned Weighbridges with re-transmission of signals / data
· Reliable Connectivity at Gates for Mobile Scanning of Trucks and Drivers
Therefore, the high-level OT scope of work to achieve the above capability is:
a) Installation and configuration of fibre connectivity to weighbridges, payment mass meters, and coal truck gates;
b) Installation and configuration of digital interfaces to weighbridges and payment mass meters;
c) Conversion of existing weighbridges to un-manned weighbridges;
d) Configuration of Plant and Enterprise Historians with relevant plant process data for coal accounting; and
e) Supply of mobile devices to workers for Truck Gate Operations.
Plant Historians
a) The Plant Historian performs various functions in the power plant for operational process data. The primary function is for long term process data storage. Another function is to act as a process data portal for external networks and services. The Plant Historian has the capability to read process data from the control system.
b) All Plant Historians are currently connected through an AOS to the Enterprise Historian. Table 1 below provides an indication of the Plant Historian installation base within the Eskom coal-fired fleet:
Table 1: Current Plant Historians Installed in the Eskom Fleet
Camden
Duvha
Hendrina
Majuba
Matimba
Kendal
Komati
Kriel
Arnot
Kusile
Matla
Tutuka
Grootvlei
Lethabo
Medupi
OEM
SAM
OSIsoft
ABB
Honeywell
Schneider
Alstom
c) During the Detailed Design Specification, the Contractor compiles a power station-specific I/O list detailing analog and binary process data required for the automation of the Coal Book, CSS and Collops i.e. coal reconciliation. This list also includes signals required to convey information on the operating and health status of the associated Plant to the PED CAS;
d) Upon approval, by the Project Manager, of the power station-specific signal list, the Employer configures the process data signals on the Plant Historians and Enterprise Historian. The Contractor accesses/extracts the process data from the latter;
e) For the scope in this section, amendments to software licenses, service level agreements, and/or maintenance agreements with the OEM, are provided for by the Employer.
Payment Mass Meters
a) In the cases where coal is delivered directly to a power plant via conveyor, payment mass meters are used as the transfer point (MP1) from the mine to the power station. The volume of coal that passes through this transfer point over a defined period of time is totalized and reconciled with the production of the mine and the stock received at the power station. Currently, the information from the payment mass meters is manually read by the mine personnel once every 24 hours;
b) The payment mass meters are located on mine premises. Table 3 provides an indication of the payment mass meter (MP1) installation base within Eskom’s coal supply chain:
Power Station
Unknown
Supported
R4 (Mine side)
Table 2 - Payment mass meter installation base within Eskom's coal supply chain
c) The payment mass meters are currently connected to PLCs at the various mines. In all cases, except for Matla Power Station, coal feed rate information for the associated conveyor belt is interfaced to the mine PLC via 4-20mA outputs on the payment mass meter integrators. At Matla, coal feed rate, belt speed, and totalized mass information are interfaced to Exxaro Matla Mine via Modbus outputs on the payment mass meter integrators. A capability similar to Matla, or better, is required for all power stations;
d) The Contractor designs, supplies, installs and commissions a PLC-based solution for interfacing the payment mass meter information, via the Enterprise Historian, to the PED CAS. The solution provides for communication/data transfer to the existing mine for plant monitoring as well. The Contractor assesses, designs, supplies, installs and commissions the interfaces to achieve this;
e) The Contractor provides and installs fibre from the provided PLC’s to nearest feasible access point to Eskom’s Business LAN. The fibre installed has at least two (2) pairs of cores available as spare after completion of commissioning. The fibre cable is suitable for the environment where it going to be deployed. Blue stripped armoured fibre cable is installed in areas where it could be damaged by physical activities of operations;
f) All components required for the fully functional solution, including but not limited to, interface modules on the PLC and the payment mass meters, splicing boxes, junction boxes, network switches, conversion modules, power and instrument cabling, or any other hardware, software, components or consumables required to realise these interfaces are provided by the Contractor, unless otherwise stated.
g) All field equipment is suitably earthed and protected against lighting strikes. No critical equipment fails in the event of a lightning strike;
h) All equipment is protected against dust and water ingress, with an IP65 rating as a minimum;
i) Network switches provided by the Contractor are rated for industrial use;
j) The totalised coal mass information shall be used by Eskom for payment purposes. Therefore, the accuracy of the totalized coal mass data on the Enterprise Historian complies with, or improves on, the existing coal supply contractual requirements between the applicable mine and Eskom. As a minimum, the information complies with the Legal Metrology Act;
k) Figure 3 shows an example of the expected mass meter solution:
Figure 3 – Example of payment mass meter interface requirements
l) The Contractor installs a PLC that monitors all the associated payment mass meters for each respective power station. For example, the three mass meters at Duvha (D1, D2, D3) are monitored using a single PLC set, and so forth;
m) The Contractor provides and installs a PLC that is 100 % redundant in hardware, excluding the backplane;
n) The Contractor provides and installs the PLC panel. The PLC panel houses the PLC and other signal conversion devices required for the automation solution;
o) The PLC panel complies with standard 240-56355815 Control and Instrumentation Field Enclosures and Cable Termination Standard;
p) The Contractor supplies three (3) fully licenced programming units for the PLC per power station;
q) During the Detailed Design Specification, the Contractor compiles an I/O list of data required to automate the existing manual capturing of conveyor deliveries from the mine to the power station. This list is submitted to the Project Manager for approval.
r) During the Detailed Design Specification, the Contractor compiles and submits design drawings to the Project Manager for approval. These drawings also include electrical drawings indicating termination points for power sources. The relevant Eskom and Mine engineers are consulted, via the Project Manager, during the development of all designs and drawings.
s) Upon approval of the Detailed Design, governed by contractual agreements between Eskom and the applicable Mine, procurement, installation and commissioning of the automation solution commences. The Employer configures the payment mass meter information on the Enterprise Historian. The Mine provides plant access to the Contractor for implementation of the works;
t) For the scope in this section, amendments to existing software licenses, service level agreements, and/or maintenance agreements with the OEM, is provided for by the Employer and the Mine, where applicable.
Un-manned Weighbridges
a) All existing weighbridges must have the ability to be operated in an un-manned manner (automated). In other words, a system is provided that allows the weighbridges to automatically identify inbound and outbound vehicles, automatically guide the vehicle to the correct weighing position on the weighbridge, weigh it in compliance with the Metrology Act without the operator’s intervention and transmit the transaction data to the PED CAS for further processing. The gate operations play an important role in this process through the use of mobile scanners and provide a check point to release the trucks for weighing;
b) The weighbridge system has the capability to automatically identify trucks and the type of load (type of commodity) they’re transporting to/from the power station. Apart from coal, other commodities transported to/from the power stations include fuel oil, scrap metal, ash and various chemicals;
c) As a minimum, the automation solution must offer the following technologies and services:
i. Automatic vehicle and commodity identification technologies;
ii. Automatic position sensing and indication system, consisting of sensors, controllers and signs/indicators to guide truck drivers onto the weighbridge;
iii. Operator consoles (refer to 3.2.6);
iv. Traffic controllers;
vi. Printers for printing of weigh-bill receipts; and
vii. Video surveillance (refer to 3.2.7)
d) In addition to the codes and standards listed in 3.1.3, the following requirements apply to the scope in c),
i. The automatic identification technologies provided are robust and proven for heavy industry;
ii. The automatic position sensing and indication system is PLC-based and is designed for 100 % redundancy and fail-safe configuration;
iii. Traffic controllers are adequately protected against accidental damage from vehicles and are fail-safe;
iv. Driver interactive displays, communications and printers are maintenance free and fail safe;
v. All field equipment is suitably earthed and protected against lighting strikes. No critical equipment shall fail in the event of a lightning strike;
vi. All equipment is network addressable and configurable; and
vii. Network switches, converters, etc. are robust and rated for industrial use.
Figure 4 - Truck Access and Weighing Automation Capability
Weighing of Trucks
a) The weighbridge terminal, also referred to as the digital indicator, shall provide the primary interface to transfer truck weight data to the PED CAS;
b) Ethernet is the preferred protocol for this interface. The Contractor designs, supplies, installs and commissions the required interface accordingly;
c) All components required for the fully functional solution, including but not limited to, PLCs interface modules, splicing boxes, junction boxes, network switches, conversion modules, power and instrument cabling, or any other hardware, software, components or consumables are provided by the Contractor, unless otherwise stated.
d) All field equipment is suitably earthed and protected against lighting strikes. No critical equipment fails in the event of a lightning strike;
e) All equipment is protected against dust and water ingress, with an IP65 rating as a minimum;
f) Network switches provided by the Contractor are rated for industrial use;
g) Any work on the terminals and related load-cells does not jeopardise their type-approval and compliance status. In the event that type-approval or compliance is jeopardised, the Contractor corrects and re-instates the type approval before Handover.
h) Table 4 - Power station weighbridge terminals details the truck weighbridge installation base at Eskom sites.
Power Station
5
Operator Consoles at Weighbridges
a) The Contractor provides an operator console per weighbridge terminal with touchscreen capability, or better;
b) As a minimum, the console allows the weighbridge operator real-time control, monitoring and alarming of the weighbridge automation systems and weighing transactions; and
c) The console is implemented in compliance with Eskom cyber security requirements.
Video Surveillance at Weighbridges
a) The Contractor installs a standalone, dedicated (not integrated into security systems) CCTV system for video surveillance of bidirectional traffic on the weighbridges. The CCTV complies with the “Specification for CCTV Surveillance with Intruder Detection” 240-91190304;
b) The CCTV system interfaces to the PED CAS through an API;
c) When triggered by the PED CAS, the CCTV system provides still images of the vehicle and incident in question. The system must be able to capture images that are clearly visible and allow text (such as that on a truck number plate) and the driver’s identity to be clearly legible under all lighting and weather conditions;
d) All CCTV cameras are of the IP-type and are PoE powered;
e) All CCTV recorders are of the NVR type with sufficient ports to cater for all cameras without the need for a switch;
f) The provided NVR’s have at least 10 % spare ports (rounded up to nearest integer) for future expansion;
g) All NVR ports support PoE; and
h) The Contractor provides all associated networking equipment, network cabling and all consumables. All network cabling provided is of the CAT5e type or better. Use of fiber and media converters can also be considered, however, the Contractor ensures that all PoE requirements are catered for.
Connectivity at Truck Gates
a) The Contractor provides wireless connectivity as the primary means of communication at the truck access gate between the mobile scanning devices and the PED CAS. The mobile scanning devices are used for scanning the driver and truck information at the port of access.
b) The Contractor is responsible for any cabling, hardware, infrastructure, consumables and configuration required to realise the wireless connectivity at the truck gates.
Connectivity at Mines and Sidings
a) The mines and rail sidings must be capable of sending data to and receiving data from the PED CAS. The data recorded and transmitted at the measuring points at the mines and rail sidings is crucial as this will enable the PED CAS to have an indication of the tonnages of coal leaving the sources, the time they left the sources and the transport information of the transporting carriers. Therefore, the connectivity at the mines and rail sidings must be stable and the information must be transmitted in real time;
b) To meet the requirements in a), a VSAT connection with an uplink speed of no less than 2048 Kbps and a downlink speed of no less than 15360 Kbps is installed as a minimum;
c) The requirements above are reasonably maintained under all weather conditions, radio frequency interference, satellite line-of-sight obstruction, lightning strikes and unexpected solar activity; and
d) The Contractor designs, supplies, installs and commissions all associated Plant and Materials to realise the requirements in this section.
Power Requirements
a) The Contractor makes provision for any power supplies and power cabling that are required for new Plant and components. This includes any power converters that may be required;
b) The Contractor designs, supplies, installs, test and commissions all power supplies, converters and cabling as per the design of the overall automation solution;
c) The Contractor indicates the requirements for bulk supplies to supply the plant/system they are designing. This would enable the Employer to allocate a feeder from the nearest available board;
d) The Contactor indicates the bulk supply voltage required, as well as any bulk supply requirements for the power converters; and
e) The codes and standards in Section 3.1.3 are complied with.
Earthing and Lightning Protection
a) The Contractor implements the correct earthing designs for safe and reliable operation;
b) The Contractor ensures that earthing supplied as part of the PED CAS solution does not void any warrantees or guarantees currently in place at the various sites;
c) All earthing designs follow the relevant OEM best practices as well as 240-56356396 Earthing and Lightning Protection Standard;
d) The Contractor tests the integrity of the earthing provided to ensure compliance to 240-56356396 Earthing and Lightning Protection Standard and the relevant OEM best practices; and
e) The Contractor provides lightning protection per signal loop for all instruments interfaced to the PED CAS as part of this scope.
Cabling
a) The Contractor provides and installs all cabling as required for the PED CAS solution; and
b) All cabling provided and installed complies with the standards specified in section 3.1.3.
c) Where Ethernet cabling is utilised, CAT5e is provided as a minimum.
Field Equipment Requirements
a) All field equipment is installed in accordance with the OEM’s instructions, the standards listed in Section 3.1.3, and industry best practices;
b) All equipment is installed taking full cognisance of the following:
i. Passageways and the movement of people and equipment during maintenance activities.
ii. Ergonomics and maintenance access to the equipment.
iii. Field equipment supports are not welded to barriers or handrails but utilise self-supported racks/stands.
iv. All equipment, component or device installations are free from vibration or suitably protected from vibration sources.
4. Performance Requirements
The sections that follow describe the expected performance requirements of the OT systems.
Automation of Gate and Weighbridge Operations
The expected performance in terms of processing trucks at the gates and weighbridges, following automating the delivery of coal by road at the power station, is listed in the Table 5.
Table 5: Expected performance in terms of processing time of trucks at access gates and weighbridges
Activity
Measure
Standing time at truck gate for access control, per truck
1 truck
10 minutes
≤ 30 seconds
1 truck
1 truck
The expected performance in terms of time required to consolidate coal information, following automating the consolidation of coal information, is shown in the Table 6.
Table 6: The expected performance in terms of time required to consolidate coal information
Activity
Performance Testing
Performance testing is required to be performed for each site. The word site implies the entire automation solution for the specific site including IT and OT as well as all mines, sidings and transporters associated with the site. The following requirements are provided for by the Contractor:
a) Group 1: For the first group of sites, the full automation solution at each site operates continuously and uninterrupted for a period of 30 days prior to Handover. Only normal operator activities/interventions to enable weighing transactions are permitted during this test period. The test shall include various scenarios to gain confidence in the system. If any defects are found or the tests fail, the solution implementation at the remainder of the groups of sites is halted until group 1’s defects are rectified and the tests pass.
b) Groups 2 to 5: On condition that the first group of sites pass the 30-day performance test without defects, the full automation solution at each site for the remaining groups operates continuously and uninterrupted for a period of 15 days prior to Handover. Only normal operator activities/interventions to enable weighing transactions are permitted during this test period. The test shall include various scenarios to gain confidence in the system.
c) On completion of the entire automation solution (all five groups of sites), the entire automation solution undergoes a 30-day performance test, where the system operates continuously and uninterrupted for a period of 30 days prior to Handover. Only normal operator activities/interventions to enable weighing transactions are permitted during this test period. The test shall include various scenarios to gain confidence in the system.
d) Should there be any defects that do not allow further operation or testing of the system and cannot be rectified on the spot, the respective performance test is repeated after addressing these defects.
e) Should there be any other defects that do not hinder further operation and testing of the system, the respective performance test can continue if plant and personnel safety are not compromised by the defects. After completion of the performance test, the defects are rectified and a 15-day performance test is carried out to verify that the defects have been corrected and that no further exist.
f) The Contractor compiles and submits a test procedure to the Project Manager for acceptance 14 days prior to the start of the test.
g) The Contractor submits a test report detailing the test conditions, test scenarios, system performance results in relation to the requirements in Sections 4.1 and 4.2, as well as any defects and abnormal operator activities/interventions carried out on the system to the Project Manager for acceptance. The Project Manager has sole discretion over the outcome of the test.
5. Reliability and Availability
a) The automation solution has an availability of 99.45 %, i.e. the system does not have a downtime of more than 2 days over a period of 365 days. No equipment, component or service can fail within a full weighing device calibration cycle due to normal use under normal operating conditions. The Contractor provides a spares list with all spares and stock levels required to be kept at each site to achieve the stated availability;
b) Lightning, dust, or water does not cause failure of the OT components within a weighing device calibration cycle. The necessary earthing, lightning protection, dust and water ingress protection is provided by the Contractor;
c) In the case of failure or malfunction, all equipment reverts to a safe state; and
d) The availability of the PED CAS is guided by FMECA studies. The Contractor facilitates and conducts these studies during the Detailed Design Specification phase and submits the respective report(s) to the Project Manager for acceptance. This process primarily analyses the requirements for availability of coal operations throughout the entire supply chain. The risk of data loss and system services’ unavailability in the event of disconnection from the PED CAS at the Power Stations, Mines, Sidings and other 3rd party sources are analysed and mitigated.
6. Maintenance
The Employer performs first-line maintenance on the system. As such, the following requirements apply to enable the Employer, Mine and Siding personnel to perform maintenance functions:
a) The system is “maintenance free” for a full weighbridge scale calibration cycle. Namely, major maintenance is only performed in conjunction with the calibration/verification of the weighbridge scale, which takes place once a year;
b) The system cleaning requirements are aligned with, but not be dependent on, the existing weekly cleaning regimes on site;
c) The system is self-diagnosing. Namely, the system triggers alarms or notifications, as a minimum, relating to:
i. Out of normal conditions;
ii. Fault conditions;
v. Network intrusion
d) For events related to plant process data, the requirements mentioned in 3.2.2 d) apply. For events related to payment mass meters, the requirements in 3.2.3 q) apply. Events related to weighbridges are configured on the Weighbridge System (refer to Figure 1 - PED Coal Automation Systems Overview);
e) Out of normal and fault conditions are actioned by the weighbridge operator via the Works Management processes at the relevant Eskom sites;
f) The Contractor provides all maintenance equipment (mobile i.e. industrial laptop/s, or otherwise) and special tools to enable on-site maintenance of all the OT equipment provided as part of the works. As a minimum, three (3) users per power station are provided for; and
7. Plant Coding
a) All new Plant and equipment installed on Eskom sites must be suitably coded and labelled using either the KKS or AKZ (whichever is applicable to the relevant site) standards listed in section 3.1.3;
b) Eskom Configuration Management facilitates the process of assigning any Plant codes;
c) The Contractor provides and installs all Plant labelling as per the standards listed in section 3.1.3.
8. Documentation
a) As a minimum, the As-built documentation listed in Table 7 as well as 240-161205767 PED CAS OT Vendor Document Submittal Schedule (VDSS) is provided, per site, at Handover.
b) All documentation is subject to review and acceptance by the Project Manager prior to Handover (i.e. during and after the detailed design and commissioning/testing phases).
c) All documentation is submitted as per the VDSS listed above.
#
4.
10.
Datasheets
11.
16.
20.
Cable block diagram (showing all main racking and network cabling routes)
21.
22.
27.
28.
36.
General
a) All documentation and designs are subject to 240-53113685 Design Review Procedure.
b) The Contractor submits a detailed method statement, including a design methodology, and highlights any deviations from the Eskom standards and requirements as a Tender Returnable.
c) Any change to an established design baseline follows the 240-53114026 Project Engineering Change Management Procedure.
d) The Contractor facilitates and conducts formal Failure Mode Effects and Criticality Analysis (FMECA) studies on all systems as part of the works. These studies are done in accordance with the requirements stated in the Eskom FMEA Guideline: 240-49230046
e) A FMECA report(s) is submitted to the Project Manager for acceptance. All FMECA recommendations are included in the Contractor’s designs.
f) The Contractor conducts risk assessments prior to any installation work being carried out.
Functional Design Specification
a) During this phase, the Contractor develops a Functional Design Specification comprising of a Functional Specification document and a System Design Report. It is the intention of this phase to finalise all requirements and subsequently document the proposed design to form the baseline for the following phases.
Detailed Design Specification
a) In this phase the Contractor develops a Detailed Design Specification, per site, for both hardware and software components of the system and specifies the procedures for testing and commissioning.
b) As a minimum, the test procedures include the following information:
i. Performance criteria;
iii. Test duration;
iv. Test conditions;
vi. KKS and AKZ (where applicable);
vii. Equipment/device technical specifications;
ix. Monitoring requirements (frequency of measurement, instrument output, etc.)
x. Availability/reliability of tested equipment over test period
c) All ad-hoc or interim design submissions are subject to Internal Design Reviews (IDR) by the Employer or any other authority appointed by the Employer.
d) Prior to any installation or configuration takes place on site, a design freeze is declared, per site, at which point the full OT detailed design pack for each site is submitted for review and acceptance by the Project Manager.
Development, System Integration and Factory Acceptance Test (FAT)
a) This phase consists of the procurement and manufacturing of hardware, the procurement and development of software, training of the Employer’s personnel, database population and system integration, which is to be followed by formal Factory Acceptance Testing (FAT) of the system at the Contractor’s/supplier's premises and Site Integration Testing (SIT), witnessed by the Project Manager.
b) The Contractor adheres to IEC 62381 for all FATs, SITs and related documentation.
c) The Contractor compiles and submits FAT and SIT test procedures to the Project Manager for acceptance 14 days prior to the start of the relevant test.
d) The Contractor is available for testing after normal working hours.
e) The Employer reserves the right to waive any test/s without consulting the Contractor.
f) The Contractor provides all Equipment, tools and software required for testing.
g) Tests that are required to be performed on a test bench are performed on a test bench provided by the Contractor.
h) System administration and user management (passwords included) are also frozen and tested during this period.
Cold Commissioning
a) Cold Commissioning refers to all the checks and tests that are required to authorise the system for safe operation after installation. The requirements below are applicable to each site.
b) As a minimum, the Contractor performs the following verifications during cold commissioning:
i. Loop checking;
iii. Protection signals functions;
v. Data interfaces; and
c) The Contractor provides all checksheets, calibration certificates, drawings and other applicable documentation for this phase.
d) The Contractor compiles and submits a commissioning procedure to the Project Manager for acceptance 14 days prior to the start of the test.
e) The Contractor provides all Equipment, tools and software required for commissioning.
Hot Commissioning
a) Hot commissioning refers to all the tests that are required to prove the expected performance and functionality of the automation solution. The requirements below are applicable to each site.
b) As a minimum, the Contractor performs the following hot commissioning tests, per site:
i. Alarm tests (and alarm rationalisation); and
ii. System maximum capability tests
iii. Functionality test
· Maintenance diagnostics and monitoring systems;
· Fail-safe testing; and
c) All associated documentation, drawings, and philosophies are available for the functionality tests.
d) The Contractor compiles and submits a commissioning procedure to the Project Manager for acceptance 14 days prior to the start of the test.
e) The Contractor provides all Equipment, tools and software required for commissioning.
Handover Requirements
a) In addition to training, items mentioned in b), c) and d) below are completed before Handover of a site automation solution is completed;
b) Performance Testing as per section 4.3.
c) As-built documentation, drawings and data packs are submitted in electronic format by the Contractor and accepted by the Project Manager as a condition for Handover; and
d) If any passwords are implemented on any of the hardware or software provided, the passwords are handed over by the Contractor to the Project Manager as part of the Handover documentation.
10. Quality
The Contractor is responsible for:
a) Developing a Quality Control Plan (QCP), all relevant Inspection and Testing Plans (ITP) and specific procedures for safety and quality assurance as required by the works.
b) Developing, within each respective ITP, all tests and inspections required to ensure that the works, inclusive of all interfaces, allow for safe operation and meet the performance requirements stated herein.
c) Providing detailed step-by-step procedures for each type of inspection and/or test. These procedures are used to assure safe operation and specification compliance.
d) Carrying out inspection and testing in accordance with the ITP and the specific procedures for safety and quality assurance.
e) Providing all necessary personnel and Equipment to perform the planning and implementation of the ITP.
f) Preparing and implementing a comprehensive, detailed inspection and testing program in accordance with the ITP.
g) Providing timely notification and allowing for witnesses to be present at inspections and tests.
h) Informing witnesses of the detailed step-by-step procedures applicable to the inspection and testing being witnessed.
i) Working only to the latest approved design drawings and utilising modification instruction forms, or approved equivalent, for modifications to designs.
j) Strictly controlling any modification of issued designs or of Plant and Material or wiring after it has been inspected or tested at any stage of the works.
k) Re-inspecting and re-testing any Plant and Material or wiring which has or could have been affected by a modification.
11. Training
a) All training is certified by the relevant OEM, authorization body, or both.
b) The training delivery methodology makes provision for both theoretical and practical training.
c) All relevant stakeholders are consulted during the development of the training modules and material.
d) The Contractor develops and provides advanced maintenance training for at least fifteen (15) personnel, per power station, on the complete automation installation (all systems and sub-systems).
e) The Contractor develops and provides advanced engineering training for at least five (5) personnel, per power station, on the complete automation installation (all systems and sub-systems).
f) The Contractor develops and provides advanced operator training (to cater for any manual intervention that may be required under abnormal conditions) for at least fifteen (15) personnel, per power station, on the complete automation installation (all systems and sub-systems).
g) The Contractor develops and provides advanced system administration and user management training for at least two (2) personnel, per power station, on the complete automation installation (all systems and sub-systems).
h) The Contractor provides hard (at least one per trainee plus 5 additional) and soft copies of all training material.
12. Technical Risks
In the implementation of the solution, the following risks are considered and mitigated by the Contractor:
Cyber Security
The cyber security assessments carried out at the power stations are based on the 9 NECR CIP security controls. Of these controls, 11 % were found to be partially observed by the power stations, while 89 % of these controls had no evidence to indicate that they were carried out at the power plants. The electronic access monitoring environment accounts for 11 % of partially observed controls. The 89 % percent of controls that have no evidence to support their implementation are in the following categories:
a) Sabotage Reporting;
c) Security Management Controls;
d) Personnel and Training;
e) Electronic Security Perimeter(s);
g) Systems Security Management;
h) Incident Reporting; and
i) Response Planning and Recovery Plans for Critical Cyber Assets domains.
Interfacing to Obsolete Weighing Devices and Plant
Where there is a risk of damage to equipment on obsolete devices or plant, the availability of replacement spares is adequately mitigated, by the Contractor, with the power station engineers prior to implementation and installation.
Plant Access for Interfacing, Installation and Commissioning
Plant access is dependent on the production requirements at Power Stations, Mines and Sidings, and is planned with the Project Manager on a frequent basis so as not hinder execution.
Installation of Electrical Cabling, Fibre, and Digging of Trenches
At present, Power Stations, Mines and Sidings have underground utilities/services. The as-built plant layout diagrams cannot be solely relied upon, and independent surveys of the selected cable routes are carried out prior to implementation. The Contractor must detail the design of the selected route after the survey on a drawing. The drawing must then be submitted to the Project Manager for acceptance. The drawing will then be used for future services when expansions, if any, are required.
Ongoing Projects
The Contractor takes note of the anticipated changes as documented in the assessment reports and provides for these changes in the design, procurement, installation, and commissioning of the PED CAS.
Measurements and Quantities