CONTENTS

INTRODUCTION WHEN TO USE DCS & WHEN TO USE PLC DCS ARCHITECTURE DIAGRAM FUNCTIONS OF VARIOUS COMPONENTS STEPS OF DCS ENGINEERING Enquiry floating Order specifications Kick off meeting System definition meeting Flow of Documents / Information from UIL to vendor for completing the job List of MCC signals Meeting with DCS vendor Freezing of Nest loading Checking of vendor drawings Pre-FAT FAT

INTRODUCTION
WHAT IS DCS / PLC ?

DCS (DISTRIBUTED CONTROL SYSTEM) / PLC (PROGRAMMABLE LOGIC CONTROLLER) IN A AUTOMATED CHEMICAL PLANT IS A WINDOW FOR PLANT OPERATOR TO CONTROL, MONITOR THE ENTIRE PLANT

FROM A COMMON PLACE I.E. CENTRAL CONTROL

ROOM.IT ALSO PERFORMS THE SAFETY INTERLOCKS OF THE PLANT.

WHEN TO USE DCS & WHEN TO USE PLC

DCS TO BE USED WHEN

Plant has more Regulatory controls i.e. more Analog I/Os.

PLC TO BE USED WHEN

No. of Digital I/Os are more.

When plant has extensive interlocking.

- PLC has faster scan time as compared to DCS - Hence used for safety interlocks

- Fail safe PLCs approved by TUV preferred for critical safety interlocks.
In case of both Analog & Digital I/Os in large nos.,both DCS as well as PLC to be used.- - DCS for Regulatory controls & PLC for performing safety interlocks. - A gateway between DCS & PLC, allows data transfer & communication between the two PC PLC systems are used for smaller plants because they are less expensive as compared to DCS system.

DCS ARCHITECTURE DIAGRAM

HARD COPIER

OPERATION STATION
PRINTER

OPERATION STATION

PRINTER

REDUDANT BUS ENGINEER'S CONSOLE CONTROLLER SUB SYSTEM I/O CONTROLLER SUB SYSTEM I/O PLC PROCESS INTERLOCKS I/O GATEWAY PRINTER

MARSHALLING RACK

MCC

MOTORS

Yokogawa Architecture

FUNCTIONS OF VARIOUS COMPONENTS IN DCS SYSTEM - OPERATOR STATION

Window between process operator & plant for plant operation. Operator station offers various tools for plant operation some of which are as follows: Graphic Overview Dynamic representation of process through which the process shall normally be controlled. Control Groups Faceplates of 8 / 16 instruments of a particular section of a plant for ease of plant operation. Trend Groups Historic / Real time trends of 8 / 16 instruments . Alarm Groups

Allows alarms of different sections / units of a plant to be grouped together for easy diagnosis. Assignable Keys For calling most frequently used displays with just one key stroke.

FUNCTIONS OF VARIOUS COMPONENTS IN DCS SYSTEM

- ENGINEERING CONSOLE Used for engineering the complete system, i.e. for building process graphics, Configuring a tag in the system, building safety interlocks.etc.
- HARD COPIER Used for getting WYSWYG copy of the operator stations screen.

- I/O BUS Network to which all the nodes of the system are connected. Each operator station, engineering station, controller, etc is considered as one node.
- MARSHALLING RACKS These are used to terminate field cables coming from junction boxes / instruments.It acts as a junction between field & DCS system. - SYSTEM CABINET Used for housing I/O racks in which I/O cards are loaded.

System Configuration Max. No. of Domain Max. No. of tags 16 Max. No. of stations/domain 64

Operator Station/HIS
General PC Console Type Control Station/FCS Standard Compact

FUNCTIONS OF VARIOUS COMPONENTS IN DCS SYSTEM

Additional components
-

AMS (Asset Management System) Batch servers History station Alarm Information Management System Web servers OPC compliant gateways Fibre optic cable Hubs and switches Sequence of Events
And Concept of software licenses

STEPS OF DCS ENGINEERING

I. ENQUIRY FLOATING While floating the DCS enquiry,following details to be specified as a minimum: HARDWARE REQUIREMENT - Analog, Digital input / output count To be worked out from the frozen P & I Ds received from PE / Licensor.

- No. of Operator stations Standard practice:

Upto 50 Closed loops - 2 Nos. >50 & <100 Closed loops - 3 Nos. However minimum 2 nos. of operator stations to be considered irrespective of plant size. - No. of printers 2 Printers - one for data logging & one for event recording - Requirement of Hard Copier - No. of Auxillary consoles for mounting of hardware PBs, lamps, annunciators, etc. - No. of bought out items like Isolation amplifiers, Barriers, Trip amplifiers, Relays, PBs, lamps, annunciators, furniture such as operator chairs, printer tables, etc.

Control Bus-Vnet-10Mbps token passing

Information Network-Ethernet
Communication ComponentAGC BCV Function Configuration Operation & Monitoring Function Control Function

System Generation Function

Communication Function OPC Active X Control Field Bus

STEPS OF DCS ENGINEERING

- SCAN TIME Time taken by the processor between successive scanning of the loop . General practice: Scan time for Closed loops & Digital Inputs / Outputs Sec Scan time for Open loops : 500 m :1 Sec

- REDUNDANCY REQUIREMENT Standard practice followed in India - Redundancy for CPU, Communication card, Power supply card, Communication Bus & I/O cards for Closed loops & critical Open loops.

Batch Control Function

STEPS OF DCS ENGINEERING

II. ORDER SPECIFICATIONS SHALL CONTAIN - All the changes / revisions made in Enquiry specifications, Model Nos. of items wherever applicable & - Any deviations taken by the vendor which are accepted during bid evaluation

STEPS OF DCS ENGINEERING

III. KICK OFF MEETING KOM should take place immediately after the order placement. The aim of KOM is - To identify names of responsible persons from Client / UIL / Vendor for the project
-

To finalize correspondence manual

To finalize format for Progress Report

Review of scheduled Progress as indicated by vendor to meet the delivery schedule. Review of BOM considered for Order placement. Freezing of vendors list for Bought out items

IV. SYSTEM DEFINITION MEETING

SDM shall be conducted at vendors works. The aim of SDM is - To understand system features / limitations
-

Freezing of makes / model nos. of bought out items included in DCS vendors scope.

Freezing of Control room layout.

Freezing of philosophy for Marshalling & Nest loading. Review of Panel layouts prepared by vendor.

STEPS OF DCS ENGINEERING

V. FLOW OF DOCUMENTS / INFORMATION FROM EPC TO VENDOR Apart from I/O list, following documents have to be forwarded to DCS vendor for completing the engineering. Software I/O list, indicating tag description, range, alarms, controller action, etc.

Interlock logic diagrams & flow chart (In case of automatic sequence)
Complex loops if applicable

Process graphics

STEPS OF DCS ENGINEERING

Graphic Specification Defines graphic philosophy to be followed which broadly includes line colour, line thickness, symbols of control valves, modifier conditions, units of measurement,

etc.
Single line diagram Indicates UPS / NON-UPS power feeders for instruments / equipment panels outside DCS vendors scope such as 4-wire instruments, package unit panel, etc.

Details of Hardwired items such as switches, lamps, annunciators, etc. Tentative layout of Shut down console.

Junction box termination drawings

Control grouping Trend grouping Alarm grouping & priority

STEPS OF DCS ENGINEERING

Information for free issue items

Shall have information such as qty. of each type of device, its Mounting details, Termination details & Wiring scheme.

Assignable keys

Allows certain frequently required displays to be called with just one key stroke.

Log Reports

consists of periodically logging a set or sets of process variables in a pre- decided format. to analyse the plant performance, calculate production, consumption of raw materials / utilities, etc.

STEPS OF DCS ENGINEERING

FREEZING OF NEST LOADING Purpose of nest loading - To assign inputs / outputs from I/O list to I/O cards. Nest loading shall be done in such a way that unless inevitable, all the inputs outputs required in a loop / interlock are in the same nest to reduce time lag required between two nests otherwise. CHECKING VENDOR DRAWINGS

This involves checking of following vendor generated documents / drawings GA drawing of Power supply rack, system cabinet, marshalling cabinets, Shut down console etc. Power distribution arrangement. Grounding requirement Graphics generated on the system Loop Drawings

STEPS OF DCS ENGINEERING

PRE-FAT

This shall be carried out prior to Factory acceptance test & all the comments on the work generated shall be given to vendor for incorporation before FAT.

FAT (FACTORY ACCEPTANCE TEST)

This is the final inspection inspection of the system where the system has to be checked / inspected thoroughly as per the specifications / engineering documents.