Plc details of agc plant

8/13/2019 Plc details of agc plant

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TECHNICAL SPECIFICATIONSFOR

NOTICE INVITING TENDER

FOR

THE SUPPLY OF

PLC BASED CONTROL SYSTEMFOR

ASSOCIATED GAS COMPRESSOR PLANT

OF

RASHTRIYA CHEMICALS AND FERTILIZERS LTD.,

CHEMBUR, MAHUL ROAD MUMBAI-71

JUNE-2013


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C O N T E N T S

SECTION TITLE PAGE NO.

I GENERAL SYSTEM AND TECHNOLOG Y REQUIREMENTS 03

II FUNCTIONAL REQUIREMENTS OF PLC BASED CONTROLSYSTEM

11

III CONFIGURATION AND TECHNICAL SPECIFICATIONS OF PLCBASED CONTROL SYSTEM

34

IV INFORMATION FROM PLC BASED CONTROL SYSTEM VENDOR 49

V SCO PE OF SUPPLY AND SUPPORT SERVICES 60

VI PREQUALIFICATION CRITERIA AND PLC BASED CONTROL

SYSTEM SYSTEM AC CEPTANC E CRITERIA

69

VII CONDITIONS AND REQUIREMENTS OF BIDDING 72

VIII OVERVIEW OF SCOPE OF SUPPLY 78


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CHAPTER I

GENERAL SYSTEM AND TECHNOLOGY

REQUIREMENTS


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OVERALL REQUIREMENTS- SYSTEMS AND TECHNOLOGY

1.1 INTRODUCTION

Rashtriya Chemicals and Fertilizers Limited, owns and operates manufacturing

fac ilities for various fertilizers and industrial chemicals at its units at Trombay

and at Thal in Maharashtra State, India. In Trombay Unit there is a turbinedriven two stage high pressure compressors of M/ s Kawasaki Heavy Industries,

J apan of 22500 Nm3/Hr capacity. Its suction pressure is 9.2 kg/cm2 and temp.

is 40 deg.C. Its first stage pressure and temp. are 21 kg/ cm2 and 126 deg.C

respectively and second stage discharge pressure and temp. are 43.5kg/cm2 and 106 deg.C respectively. High pressure compressor is driven by

back pressure turbine. The final discharge gas is supplied as a process gas toAmmonia-I, Ammonia-V and Methanol plant.

It is proposed to replace existing Electro-Pneumatic control system.

Hazardous area classification for Associated G as Compressor plant is Zone 2Gr.II C.

1.2BACKGROUND

Presently Electro-pneumatic Relay based is used in the plant for monitoring

and control. The safety interlock logic system is implemented through discreteRelays. Conventional Pneumatic vertica l panel for operators are located in

the control room. It is proposed to replace existing control system with state of

the art PLC based control system. The system incorporate trip interlocks as wellas Analog controls inclusive of Customized Anti-surge control logic related to

the process of the plant.

1.3SCOPE

This specification covers general requirements for the PLC based controlsystem & its auxiliary equipments to be supplied for the above project. The

scope includes design of system hardware, software, spares, Manufacturing ,testing at factory(FAT) & at site(SAT), documentation, training, erection &

commissioning of control system, system integration, maintenance contract &

other necessary items to make the system operable & complete to the

satisfaction of owner. Offers are to be submitted for the two optionsseparately system as illustrated in schematic diagram for proposed:


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Transportation of system cabinets, other cabinets, operating/engineering

stations, Annunciator panels to Associated Gas Compressor plant control

roomshall be done by vendor..Unpacking of all cabinets.Storagecabinets,

Storage of cabinets inside system room before start of shutdown andpositioning/fixing of panels,Disposal of wooden packings to RCF scrapyard

scrapyardon frames,shall be done by vendor.

glanding of interpanel wiring,cable termination.

TRANSPORTATION/WALKWAY

LCP LCP

COMPR B COMPR A

SYSTEMROOM

WAY FOR

Ethernetapprox..50 Mtrs.

COMPRESSOR HOUSE

SCHEMATIC DIAGRAM FOR LOCATION OF SYSTEM ROOM & LOCAL

CONTROL PANEL(LCP) FOR ASSOCIATED GAS COMPRESSOR PLANT

AIRCONDITIONER ROOM

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Vendor shall perform on site testing (OST) before making power on.Detailschedule of activities pertaining to OST shall be approved during kickoff

meetings.

Actual plant shut down time available shall be a maximum of 5 days. The PLC

based control system contractor has to commission the system working roundthe clock in this period only. It is to be noted that switching from existingpneumatic control system to new PLC based control system within minimumspan of time is the essence of work.

The vendor shall supply all PLC based control system equipment, input/output

panels, complete with marking of cables and internals. It is also within the

vendor's scope of supply to perform all the necessary applicationprogramming including the development of graphicprocess graphicprocess

flow sheets, trends, control groups etc . The PLC based control system and thevarious panels shall be designed, manufactured and tested in accordance

with this specification and the relevant Instrument Data Sheets anddocuments.

During detailed engineering work, building of graphics, the vendor is obligedto integrate involvethe owner's personnel in order to ensure a smooth hand

over of the PLC based control system. This should include training in

maintenance and reconfiguration of the system. The vendor is obliged toparticipate in installation on site.

RCF shall furnish following information to vendor for applica tion development:

1) Documentation of Input/ Output database as hard / soft copy

2) Documentation of wiring diagram/ write-up/ logic/ sequence/ controllogic /proc ess interlocks.

3) Approval of documents/ formats as identified during Kick Off meeting

1.4 TECHNOLOGY AND OBSOLESCENCE

The PLC based control system to be supplied shall incorporate advance state

of art technology that shall guarantee freedom from obsolescence at leastfor 15 years. Furthermore, the intelligence shall be extensively distributed up to

the field level.

The PLC based control system to be offered shall be the latest in last 3 years &in the ongoing the product range of the foreign principal of the supplier/OEM.

The bidder shall certify that the product offered is the latest and proven in

their PLC based control system family. Any impending product launch shallalso be indicated in the bid, along with features for up gradation

compatibility. The offer is liable to be rejec ted if the system offered is not the

vendor's latest PLC based control system product or if prior information is notfurnished about impending launch of a new system.

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1.4.1 Use of standard Procedures:

a) The system shall be composed of manufactures own standardhardware, systems software which can be configured to meet the stated

requirements.

b) Vendors standard operating system software shall not be modified to

meet any of projects requirements.

c) The vendors system shall be designed in a manner such that the

implementation of application software requires no modification to the

system operating software.

1.4.2 Field Proven Systems

All hardware, software and firmware supplied with the system shall have been

field proven prior to placement of order; Field proven is defined as successfuloperation at a field installation of 24 or more months.

a) This requirement does not apply to the applica tion software to be

developed for the project.

b) Vendor shall guarantee that he will support all system hardware and

firmware with spa re parts and service for a period of 15 years from placement

of order or 10 years from end of warranty, whichever period ends last.

1.4.3

Distributed / Open ArchitectureThe PLC based control system shall permit control, data acquisition and

control functions to be performed at remote locations while providing thecapability to monitor and control the distributed functions from a centralcontrol facility. The system shall be sufficiently flexible so that it can be

configured to a wide range of process requirements at the loop and

component level without changes to the hardware.

The PLC based control system shall be based on on open systemarchitecture. The open capabilities shall also allow third party software (such

as operator interface, optimisation software or expert systems) to be anintegral pa rt of the systems when RCF intends to procure them.

Communications with other devices shall be via industry standard protocols.

System shall be capable o f hosting various industry available communication

protocols with third pa rty systems. System shall be capable of installingcommunication module/ software in future.

1.4.4 Spare Capacity and Expansion Capability


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The PLC based control system shall be delivered to the installation site with the

following minimum spare capacity and expansion capabilities.

A) Spare Capacity

a) Redundant capacity is not considered to be spare capac ity.

b) Process I/O racks shall contain 20% installed spare with fully wired all I/O

modules. The module types shall be provided in the approximate ratioof non spare types and d istributed throughout the I/O racks. Other

system components to support the spare I/O such as Process I/O power

supply capacity, terminal block, I/O cables, I/O communications, etc.,shall also be installed with 20% spa re capacity. If terminal blocks are pre

wired to the process I/O then these shall also be pre wired to thespare I/O.

c) Proc ess I/O racks shall have an additional 20% spare rack spacein each

type of IO rack for further addition of any type of I/O card in

corresponding I/O rack in future. only, without installed modules. Thisspace shall be used for installing any type of modules of any mix.

d) Process control device shall be sized such that no more than 60% ofprocessing capability and memory is utilized. Vendor has to submit theCPU loading ca lculation.

e) Cabinet, which contain terminal blocks, shall be provided with 20% spare

terminal blocks . and space to install additional termination

corresponding to utilization of spare rack space by addition ofcorresponding I/O cards..

B) Expansion Capabilities

a) The system design shall include the capability for at least 25% future

hardware expansion (relative to the bid), which shall be achieved by

addition of equipment, without modifying or replacing existingequipment, communica tions cables or system operating software. This isin addition to the spare requirements of section 1.4.4 a)

b) Each installed communication system shall have 25% node expansion

capability for future development and still be capable of meeting therequirements of this specification. The vendor shall provide estimated

loadings of the communication systems to substantiate this requirement.

c) The system processing and memory capacity shall have 50% expansioncapability for future application programming and configurationincluding, but not limited to, the following: Alarming / Monitoring,

Equipment Monitoring, Trend and history collection, Reports, Displaysincluding user defined graphics displays.


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The PLC based control system shall be delivered to the installation site with thefollowing minimum spare capacity and expansion capability.

1.4.111.4.5 Software Protection

No software locking mechanisms, which would restrict the user from copying

the software source or compiled executable code from the storage media,

shall be employed. No software locking mechanisms, which restrict the userfrom booting (starting Up), shall be employed. This means that no key disks

or password or USB dongle shall be required to use the software supplied aspa rt of the systemfor process control and for Engineering configuration.

Operational security is different than software protec tion. User programmable

operational securities to be provided at various levels of PLC based control

system configuration

1.4.121.4.6 Software Revision Levels

a) The vendors standard system operating software delivered to the

installation site shall be the most recent field proven revision levelavailable at the beginning of the Pre Factory Acceptance Test (FAT)

which is applicable to the system hardware.

b) The system shall allow for upgrading of system operating software on all

redundant modules of the system without necessity of shutting down the

process, without losing the window to the process (operator interface)

and without losing any control functions.

1.4.131.4.7 Third Party Equipment

All equipment provided as part of this system that is not manufac tured by theVendor shall be latest model of of current manufacture by the original

equipment manufacturer Vendorat the time of placement of contract or

order, that is, it shall be currently available for sale from the original

manufacturer at the time of placement of contract or order. All such

equipment shall meet all applicable project specifications and standardsreferenced in this specification.

1.5 OPEN ARCHITECTURE DESIGN


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The PLC based control system to be offered shall conform to open

architecture design.

1.5.1 Ethernet

It shall have provision of IEEE 802.3, Deterministic and Real Time RedundantEthernet 100 MBPS and TCP /IP protocolsfor communicating with MIS systems,

controllers, operator & engineering stations printers, third party devices.Ethernet shall have capabilities to detect & self-rectify faults for undeterredcommunication to various intermediate nodes on network.

Extension of Ethernet for provision of operating stations/Remote I/Os shall be

implemented through Fibre Optic cable.

1.5.2 Migration

Migration to open standards as stipulated above shall be possible at themodular level (for each node on the system highway) and shall beachievable with the minimum of hardware.

1.5.3 Conformance

Conformance / seamless migration to oOpen architecture is an importantrequirement of this tender. Failure to comply with these specifications or

failure to indicate a cost effective and seamless migration to open

architecture would make the offer liable to be rejected.

1.6 PROVENNESS OF THE SYSTEM

The system to be offered shall be a proven system which shall already beinstalled and in operation at least for three years in India in a continuous

process industry for similar operation of turbo compressor. The bidder shallsubmit details of such installations with references of the companies, size,

value of orders, no. of years in operation etc. and contact persons namecommunication details.

The bidder shall have had competent and proven expertise in supply,

commissioning and servicing of comparative control system in India. Details

regarding commissioning/service personnel & training facilities essentially

needs to be provided by the vendor. . A service office in Mumbai shall be

essentially preferred and bidder to provide the details of Mumbai service

organization like No. of service engineers and customers being supported in

Mumbai Region.


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CHAPTER II

FUNCTIONAL REQUIREMENTS OFPLC BASED CONTROL SYSTEM


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2. FUNCTIONAL REQUIREMENTS OF PLC BASED CONTROL

SYSTEM

PRECEDENCE OF SPECIFICATIONS

The ob jectives and broad guidelines laid down in this section define endgoals of the purchase of the system. This Section o f this NIT shall prevail over all

subsequent sections. The supplier shall therefore be guided by thesestipulations and in the event of a conflict between this section and any item

in the subsequent sec tions; those given in this section shall prevail.

2.1 CONTROL FUNCTIONS

All the controllers shall have built in redundancy function with high speed

communication link between primary and secondary controllers. Controllersshall support Ethernet communication with operator/ engengineeringg./server

stations.

All the controller modules shall be capable of performing at least the

following functionshowever not limited to:

a) Data acquisition from I/O modules.b) Regulatory PID control with different types (both direct & reverse acting

type)

c) Ratio control ,sequence controld) Cascade control

e) Feed forward control

f) Anti-reset windupg) Lead-lag co ntrol, Time lagh) Arithmetic function like +,-, X, / , etc.

i) Auto manual bumpless transfer.

j) Manual output ramp

k) Logic functions like AND, OR, NOT, EXOR etc . High, low selector functions.l) Characteriser bloc k

m) Alarm setting of different parametersand masking of individual alarms

with out changing the alarmset points.n) Displaying of the tuning parametersand facility to tune the c lose loop

with a trend window so as to observe the loop performanceetc.

o) Squa re-root extraction/flow totalizer

p) Input signal conditioning

q) Adaptive control, Auto tuning.

r) Antisurge control algorithm for 2 stage centrifugal compressors) Pressure/ temperature compensation for flow

All the above control functions shall be available in the form of algorithms

and it shall be easily (software) configurable by the user. The PLC based

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control system shall have the capability of converting various input signals intotypes, which are of direct use to the system.

The functional block configuration should be kept to max. 50% and data

ac quisition cards to max. 70%. The total system loading for controller and

data acquisition subsystem shall not exceed 60%. The loading indicated hereis the worst case of high system activity referred to the use of memory, CPU

time and communication capacity for the sub-system.

Complex loops: Algorithms for these shall be written along with the purchaser.

Built in redundancy is required for following:

Closed loops/:Processor/controller ---- 1:1

Memory ---- 1:1Power supply ---- 1:1

Data highway communication ---- 1:1System bus ---- 1:1

AI/AO/DI/DO cards ---- 1:1

I/O Bus with controller ---- 1:1Open Loops:

Processor/controller ---- 1:1

Memory ---- 1:1Power supply ---- 1:1Data highway communication ---- 1:1

System bus ---- 1:1

I/O Bus with controller ---- 1:1

Server grade for MMI: ---- 1:1

Failure of a single channel shall not lead to the loop to be taken to manualmode for operation as the whole concept of automatic control resulting in

low availability of system.

Redundant ca rds of every kind shall be kept on line all the time and shall take

over in bump-less mannerinstantaneously and automatically in case of failureof the active card. Furthermore, any configuration changes made on activecontroller should be automatically & instantaneously cop ied to the redundant

standby controller. Design must ensure that data integrity is maintained during

switch over and no portion of data to be transferred is corrupted before andduring switch over to the backup controller.

In addition, vendor shall guarantee the non-existence of any non-redundantdevice whose failure might affect the whole systemsoperation or reducethe operators monitoring capability.

The controller upda ting time shall be 0.1 to 0.5 seconds user definable) for

all the loops connected to it. There shall be hot standby for each controller


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and associated cards (such as memory card, communication, switch-overcontrol card, etc.) and the standby shall take over smoothly in the event of

failure of the working controller. The controller modules shall have redundant

power supply. The communication from the controller shall be redundant.

The controller should be capable of executing more than two (2) scan ratessimultaneously.In case the controller does not have such feature, an extra

controller to be provided per area / group.

The controller should be equipped with additional redundant firewallbetween controller and proc ess network safeguarding the controller from any

unwanted data.

Third party interface provision with necessary independent hardware (serial

controller / Gateway)/ software for 3 serial interfaces shall be madeavailable.

It shall be possible to download the data contents of the controller on to a

mass storage device and same shall be reloaded automatically on to the

controller to prevent loss of data during prolonged power failures. Thedownloading / reloading operation shall be fast and shall be possible from

any station console. Failure of any controller should be indicated / printed

on operator / engineer station with audible / voice alarm and shall bedisplayed locally. The system should reboot itself automatically if the power isrestored.

The controller should have the output hold facility to maintain the last output

value in case of failure of both the main / redundant controller. The I/O ca rd

shall also hold / be configurable to fail-safe condition in case of both main /redundant cardsfail. Communication between controller and I/O ca rds shall

be preferably of proprietary nature for software safety purposes. Controllersand I/O cards shall have separate physical identity.

Process control & emergency trip interlock shall be incorporated in PLC based

control system controller and not in communication controller. All logic

operations and all regulatory and process monitoring functions shall beperformed in same controller of PLC based control system. The plantEmergency shutdown system will be based on proposed interlock system with

a minimum of manual / local control.All logic and sequence operation shall

be c hecked from input to output by forcing / enabling various inputs/outputsduring pre-FAT / FAT. All triop related I/Os shall be segregated in I/O

assignment such that trip related I/Os shall be terminated in redundant cards.

These ca rds shall not have I/Os which are not related to plant tripping.

Set point and PV tracking shall be a standard feature. The controller shall be

able to operate in manual, auto, cascade or computer mode. Modechangeover in either direction shall be procedure less and bump-less. It shall


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be possible to change set point, tuning constants, controller mode, andcontroller configuration from operator / engineer station.

When operating under external supervisory mode, controller shall be able to

trac k computer generated set-point and hold last generated value in case of

computer failure. In such a case, controller shall fall back on auto mode andcontinue to operate at last received set point, in general. Other options like

pre-defined set-point operation and fail safe condition shall also be possible.On the resumption of computer, the controller shall not return to external

supervisory mode automatically. Computer failure indication shall beprovided on all stations .

In cascade loops, primary controller shall be able to track the set point and

output of the secondary controller when secondary controller is not operatingin cascade mode.

Rail powered type IS barriers of P&F shall be provided for all I/Os to complywith hazardous area classification (Zone 2, Group II A/B, T4) spec ified for

Methylamine plant.Common Rail powered type IS barriers with two power feed modules with

every set of rail for P & F make IS Barrier shall be provided for all I/Os to comply

with hazardous area classification (Zone 2, Group II C, T4) specified forAssoc iated Gas Compressor plant.

2.2 ALARM FUNCTIONS

The control system shall be capable of warning the operator of any abnormalprocess conditions or internal control system failures.When any process alarm occurs the operator shall be warned by an audible

sound. Alarm sound shall not be produced by speakers of Operator StationPCs but by separate electrical Hooter. individually installed on all 3 operating

stationPCs. It shall be possible to acknowledge and silence the alarm from

any station

Once the display in the alarm has been accessed, the operator shall

acknowledge the alarm by depressing the acknowledgment button / key.

The audible signal might be turned off by a dedicated key.During start-up and shutdown of the plant, it would be convenient if the

operator is able to mask certain groups of alarms which are not required. An

alarm system at startup with such feature shall be preferred.Operator shall

be able to enable/ disable every alarm individually.The system should alsohave capability to produce different type of a larms related to hardware and

process.

Certain alarms may require action by the operator. The alarm system shouldhave the facilities to create an "Operator's Guide", in which the operator can

find instructions to overcome operational problems identified by the alarm.

A text message page shall be provided to communicate instructions tooperator which will be accessible at single click of a button.



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2.3 INPUT-OUTPUT SYSTEM

All the input output blocks / modules shall be mounted in a single / multi racksystem connected to a common communication highway. All I/O cards shall

be separate. The system shall support the following type of input and output

signals. Configuration of I/O modules shall be through engineering station and

not by local configuration in I/O card modules.

2.3.1 Inputs

a) 4-20mA DC Based 2 wire & 4 wire

b) 1 - 5 V DC

c)

All types of thermocouple /RTD /mV inputs converted to 4-20mAcurrentd) Pulse input

e) Potential free contacts

f) From special analytical instrument

g) Capability to communicate with Vvarious communication ports suchas

Modbus, RS 232, RS 485 etc. for digital communication with various

devices in the plant i.e. analysers, optimisation system, PLC based

control system etc.Suitable hardware/ software shall be supplied onchargeable basis if required.

It shall be required to develop the necessary software drivers for such devices

in PLC based control system; the vendors should not withhold any informationto other manufacturers regarding their protocol for developing interface

between the two systems.

PLC :All tripping interlocks shall be configured in ladder programming and not

only through function block. DI & DO need to be indica ted Online on ladderlogic so as to facilitate common functions such as forcing/simulation/ timer

value change etc. Display of PLC in ladder logic is required for

monitoring/manipulating all functions of PLC. Configuration in only sequence

tables is absolutely not acceptable. Online changes in PLC ladderconfiguration shall be possible without holding controller execution orstopp ing PLC sca nning.

2.3.2 Scan Time

Scan time for a closed loop shall be the cycle time taken by controller to

read, analyse or manipulate the and process input, perform control

calculations and update controller output for loops configured within the

controllers.

Sca n time for an open loop shall be the c ycle time taken by data acquisition

system to read, analyse or manipulate the andprocess inputs and perform





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computations of all open loops configured within data acquisition system.Forsystem for various controls and data acquisition parameters with the

following or lesser better scan time shall be used.

Sequence of events recording is not required but first out indication is

required.

Vendor shall submit detail scan time calculations during initial technical offer

failing which offer may be summarily rejected. Vendor shall submitdocumented copy of standard product catalog to support scan time

ca lculations. Sufficient number of controllers/power supplies & otherredundancies need to be offered as per the number of controllers.

Close Loops :

a) Close loops : 250 msec. or better

Open loops :

a) Analog Inputs (4-20 mA) : 500 msec.or betterb) Digital Inputs : 50 msecor betterc) Temperature Inputs : 1 Sec or better2.3.3 Outputs

a) 4 - 20 mA DC

b) Potential free contacts controllable from operator stations for manualstart/ stop etc . Both latched and momentary contacts shall be available

Each input/output blocks / module shall be provided with, but not be limited

to, following functions.

a) Signal filtering

b) Signal conditioning like square root extrac tion linearization etc.

c) Alarm setting-low, very low, high, very high, on measurement, set point,output etc.

d) Limit checking

e) Biasf) Integration of pulse inputs from the flow transmitter.

g) Data acquisition.

h) Trending - Real & Historical.i) Pressure, Temperature, compressibility fac tor correction for flow inputs.



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All the output cards shall be able to give the output values from -5% to +105%

i.e. from 3.2 mA to 20.8 mA.

The input/output blocks /modules may be of single I/O type or multi I/O type.

All the input/output cards shall have configurable 2 wire/4 wire transmitter

featureand supply power to the required transmitters/I-P converters.

The actual input output requirement is listed below. All I/O systems shall have

redundant power supply. The I/O redundancy for closed loop control shall be1:1 in the case of multiple input/ outputs per card .

2.3.4 I/O Cards

The I/O cards shall be connected to the terminals by means of prefab cables.

I/O redundancy is required for all the c losed loops as well as certain critical

loops.

I/O cards shall have built in galvanic / optical isolation for input and output.

I/O cards need not be HART compliant by Hardware/software.

No special corrosion resistant coating are required as per NIT. Even thoughvendors can offer ,products with special coating. No special credit shall be

given for any such product.

All the field instruments are located in Zone 2 Gr.II CClass 2 Gr.IIC hazardousarea. Suitable barriers shall be provided for Zone 2 Gr.II C C lass IIC area

classification.

The input card shall perform all types of linearization viz. square root, T/C, RTD

as per channel basis.

The I/O card should also hold / configure to fail-safe c ondition in case of

failure of both main / redundant card. The output ca rd shall perform output

sca ling, d irect / reverse output.

Digital Input / Output cards shall have following features

a) All the digital inputs shall be potential free contacts. Digital input card

shall provide interrogation voltage to the input.b) All digital outputs shall be potential free contacts with contact

rating 230V AC , 5A. Power supply 24 VDC shall be routed through

REGULATED POWER SUPPLY 24 vdc IN SCOPE OF THE VENDOR.

Individual I/O card shall have visual status display indication for healthy, card

fault, communication healthy and communication fault.



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I/O card racks shall have expandability. The card rack shall not be loadedfor more than 80 percent capacity.

I/O ca rds shall be mounted in rack such that connections of 2 cards shall not

overlap . Removal/testing at card screwed termination shall be possible

without removal of other wires.

DI/DO coming from Annunciator cabinet shall be connected to system

through Remote I/Os through Ethernet.

2.3.5 List Of I/O Count

Sr.No.

TYPE OF SIGNAL ActualQty.

20%extra

Total Redundancy

(YES/

NO)

Barriers(YES/

NO)

1.0 Close Loop

Analog

1.1 4-20 mA DC, Twowire Analog Inputs

(AI)

13 3 16 YES YES

1.2 4-20 mA DC, Twowire Analog

Outputs (AO)

13 3 16 YES YES

2.0 Open loop Analog

2.1 4-20 mA DC, Twowire Analog Inputs

(AI)

50 10 60 NO YES

2.2 K & J typeThermocouple

(T/Cs)& RTDAnalog Inputs (AI)

converted to 4-20

mA signals using

universal

50 10 60 NO YES

Formatted:Right: 0.25 cm


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converter P&F

make ba rriers

2.3 Digital Inputs (DI) 45 9 54 NO YES

2.4 Potential FreeDigital Outputs

(DO) with relays

10 2 12 YES NO

2.5 Potential FreeDigital Outputs

(DO) directly to

the annunciator

32 0 32 NO NO

Following table indicates Remote I/Os (DI/DO) ,in case ofAnnunciator/pump control panel resides on ETHERNET, same

quantity shall be deducted from the DCS DI/Dos if RCF opts forextended ETHERNET configuration. This optional item shall be

offered separately by vendor.2.0 Remote I/Os (DI/DO)

2.4 Digital Inputs (DI) 45 No No

2.5

a

Potential Free Digital Outputs

(DO) with relays

33 No No

P&F make universal temperature converter/barrier shall be used for

interfacing of thermocouples/RTDs. These barriers shall be programmable so

as to select range, type (J /K T/C /RTD, etc.), output, etc. for each barrier

individually. Necessary hardware for programming ba rriers such as anadaptor to connect to a PC/ laptop a nd programming software shall also be

provided.

These ba rriers along-with other barriers required for DI, DO, AI, AO shall beinstalled on Power DIN rails. P&F make Power feed modules shall be used in

redundant configuration so that each DIN rail segment shall have redunda nt

power supply

Distribution of a truly redundant fail safe 24 V DC power supply shall bevendors scope.

For all redundant I/O cards, number of I/O channel shall be as permanufacturers standard. However, maximum number of channels shall be

16 for analog cards and 32 for digital ca rds.

Separate modules to be provided for AI, AO, DI, & DO for open loop as well

close Loops.

All I/O cards shall have capability for redundancy. Even I/O cards for non-redundant open loops shall be such that they can be configured for

redundancy in future if required.


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Required numbers of input/ outputs are without spare capac ity. All theseinput/ outputs cards shall be wired/ installed in the system.

2.4 OPERATOR STATION, QTY :QTY:2 NOS.

Operators will monitor the process and initiate all control functions from

operator stations. All monitors and keyboards of operator stations shall be

identical. They shall provide colour graphic, control, and display and alarmfunctions. It shall be possible to change control assignments to allow control

of any plant area from any operator station by using the appropriatepassword at various level. All engineering functions shall be possible from

both the Operator Stations.

Each operator station shall have direct independent access via dualredundant communication path to the controller and not via the Engineering

station.

Operator station make and acceptable is only Dell make server grade PC-12th generation, RAID-5 Configuration. Server grade operating system -2012,

RAM 8GB, HDD-500GB and dual redundant power supply with 24 LED

monitor.

As an optional item; for each operating station, Vendor shall provide CE 770

ATEN MAKE or equivalent USB KVM extender with deskew function. The

automatic signal compensation and RS232 serial functionality allow access toa computer system from a remote USB console. Local & remote units connectat distances up to 300 mtrs.

Each Node where history resides should be minimum RAID 5 hardd iskhard disk

configuration to ensure maximum availability of history.

Operator station (also Engg. Station) shall be with latest WINDOWS based

proven system.(Vendor shall furnish list of minimum one working systems in

continuous proc ess chemical/fertilizer/refinery industry for OS other than

Window) The Operator station shall be provided QWERTY Keyboard & Mousefor navigation & operation. All displays shall be accessible from LED Monitor ofthe station connected to the same data highway. 24 LED Multicolour

displays are required.

Party shall offer their own HMI software. Third Party software is not acceptable.

The system shall have flexibility in specifying or changing the tag numbers,

descriptions, ranges, scale fac tors, or grouping in the various displays.

Each display shall always provide the following features:

a. Time of day in hours and minutes



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b. Date by day, month, yearc. Year shall be displayed in 4 (four) digits, e.g.1999, 2001 etc.

d. Page number, if multi-page displays are used.

All rea l time clocks in the system shall be synchronised from one clock

source.

Each LED screen shall be able to display full alphanumerical tag no. ofprocess variable. A min. of sixteen (16) digits shall be required for tag no. and

min. 30 digits for process description as per example given below:

Tag No. : 20PIC1501

Description : 20T501 PRESSURE

When configured in operations mode, the operator shall be able to perform

following main functions from these stations:

a) Monitoring/controlling of the entire plant (Regulatory and Supervisory).

b) Trend display,c) Alarm Display and print out

d) Report generation

e) Graphics capabilityf) Computationg) Multi window capability

h) Dedicated alarm view availability while operating through graphics

i) General Features

Pump remote/ local & start/stop interlock logic, process tripping interlock shall

be incorporated in PLC based control system and graphical presentation oflogic shall be available on Screen. Pump Auto /Manual, local/remote pump

selection shall be through local control panelauxiliary console. Pump runningstatus (Red/green colour)shall) shallbe available on PLC based control

system.Existing Interlock diagrams shall be given to vendors along with Tag-

names of assoc iated field instruments. PLC based control system vendor shallincorporate the same in the controllers.

Also, provision of Emergency plant trip push button along with its linking in

interlock logic for initiating plant trip is required.

The details of the above functions are listed below:

2.4.1 Monitoring / Controlling

Dynamic Display of the entire parameters as given below shall be available:



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a) Overall view of the Plant.

b) Area shall show the graphic & numerical values with Engineering

units wherever applicable, each pa rameter (measurement, set

point) and alarm status of each area of the plant.

c) Group - shall include, apa rt from those mentioned in area display, thedeta ils of controllers and its alarm status. It shall provide the operator

with a display of up to 8 control instruments per page in a formatresembling a conventional control panel. In addition to controllers

certain important indica tors may be shown on group display. The

group display shall represent a bar graph and other indications ofeach loops process variable, set point and output values. The

group display shall include the group number and title, and shortdescription for each loop or variable displayed. The mode o f eac h loop

(Manual/ Auto / Cascade etc.) shall be shown in the group display.

It shall be possible to control process from group display. Following control

ac tions shall be possible from group display.

I. Increase / dec rease set point

II. Change controller modeIII. Change controller output in manual modeIV. Start / stop or open/close command for digital points.

d) Loop - shall include the details mentioned in area & group displays and

the complete loop details which include measurement, set-point,

output values, mode of the controller, tuning parameters etc. It also shallinclude process variable minimum and maximum values, alarm set point,

limits on set point, output & velocity, controller action(Direc t/Reverse),computational constants like bias, ratio, integrated value (Total),

Engineering units.

Following actions shall be possible from Loop display.

I. Increase / dec rease set pointII. Change controller mode

III. Change controller output in manual mode

IV. Start / stop or open/close command for digital points.V. Change tuning parameters

VI. Change limits on set point, output and velocity

VII. Change alarm set point

There should be provision of conversion of QWERTY Keyboard buttons to

ded ica ted function buttons to increase / decrease output / set point at fastrate (upto 4%)and slow rate (minimum 1%).


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Also it shall be possible to increase / decrease output (in manual mode) / setpoint (in auto mode) from controller bar graph display faceplate by use of

mouse pointer.

In group/ loop d isplays controller tags shall have auto/ manual / cascade

mode selection soft targets by default. This should not be an engineeredsolution.

Loop display shall also contain a trend displaying Process value, Set value

and Output with sample time of 1 second and full time scale of 60 minutesfor tuning of process control loops.If changing of tuning parameters of PID

loops requires add itional software same shall be offered.

Set point/ Output tolerance check- If Set point of a controller and its output

in auto / manual mode is changed by 10% or more than its previous valuesystem shall have facility to warn the operator and for ask for confirmationfor such change. Warning shall be displayed so as to clearly indicate inbold.

The system shall provide a screen update time not exceeding 1 sec. Anyloop with high deviation or high low alarm shall be shown by a visual

alarm. The operator shall be able to manipulate the set point, output, and

control modes of any loops shown on a group d isplay by the appropriatekey entries.

The operator shall be able to create and display groups in addition to those

in overview display.

2.4.2 Trend Display

Trends shall be easily configured online through standard trend displays,

without the need to build spec ial displays.

Real-time and historical data shall be presented together on the same trend.

Archived history may be accessed automatically by simply scrolling to, or

directly entering, the appropriate time and date. Users shall be able to copytrend da ta to o ther applications such as Microsoft Excel.

The simultaneous historical trending of a t least sixteen eight (816) selected

variab les shall be possible on any operating/engineering station withselectable sca les and colours, per trend, and with selectable sampling rates

(min. 1 sec )for all the AI, AO , DI & DO tags with minimum archiving period of

3 months.

The real-time trending shall be available for a ll the parameters of all the

loops of the plant. However, user shall have the flexibility to assign andreassign any of the loops to the real-time trend database.



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The real-time trend shall have a minimum scan time preferably 1 sec and the

display time frame shall be user definable from 1 minute to 2 hours. Duration

of real time trend shall be minimum 30 days. Sampling rate shall be

selectable.

System shall provide history collection over a wide range of frequencies in

both average and snapshot/production formats. Large amounts of historyshall be retained online, with automatic archiving, allowing retention of and

access to unlimited quantities of historical data. Archive data can be storedon a variety of storage devices, not other than following:

Local or networked hard drives Optical media

ZIP or J AZZ drives

System shall store the values of points over time at regular intervals, between 1to 30 seconds as well as averages of the 1-minute snapshots at intervals of 1

to 24 hours.

The period of time that this historical data is stored shall be selectable. User

shall be able to archive this process history to off-line media such a

removable disk so that the history can be restored later if needed.

It shall be possible to magnify the trend values by assigning a user-defined

window with lower and upper limit of the trend value range (i.e. magnify a

part of the trend screen). A vertical marker / po inter shall be possible on

historical and real time trend to pinpoint the value at any point on the trend.

Scrolling, windowing, digital value display at selectable sampling times andzooming features shall be provided.

Trend display should indicate value & time on cursor movement.

2.4.3 Alarm Display

System shall provide comprehensive alarm and event detection,

management, and reporting facilities to speedily target the source of theproblem, allowing the operator to focus on the data of interest in times of

urgency. Following features are required:

Controller-based alarming.

Multiple alarm priorities.

Standard notification displays of alarms, events, alerts, and messages. Most recent alarm zone displayed on every screen.

Advanced alarm management such as the ability to:

Launch assoc iated graphic and point detail display on alarm for instant

context

Log the return to normal status



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Filter alarms (for example, by priority, asset, and a cknowledgment status)

Log to track operator-initiated actions

Configure and view aggregate a larm counts

Alarm groups shall be available as an alternative way of viewing areas and

alarms associated with areas.

All stations shall have the facility to set the alarm limits (such as low, extralow, high, extra high etc.) for all the process variables as well as set point,

output and deviation on the above three variables. System shall display thealarm conditions based on the above parameters.

The Alarm Summary Display shallprovide the operator with a summary of

process alarms in an operator station group in an order of occurrence. Thedisplay shall show the following items for each point:

a) Tag number

b) Type of alarm (when point is in alarm)

c) A description of the pointd) Date and time of occurrence

All the alarms shall be accompanied by audio/voice announcement till the

same is acknowledged. It shall be possible to selectively silent any alarmfrom any station.

The alarm condition shall indica te the point(s) in alarm by flashing red or

reverse video character and/ or the tag number. Priority alarm & standardalarm conditions should be separated. When the alarm is acknowledged,

the flashing display shall become steady. The display shall return to normalwhen an acknowledged alarm condition returns to normal.

System shall have blinking fac ility for all the a larms. The alarm cond itions shallbe ava ilable in all the area, group & loop displays. Different audio tones shall

be available to distinguish between different areas or types of alarms.

Alarm/Event Printer, Qty.: 1 No.

System shall print a summary of alarms and events to common alarm/event

printer as and when desired.

System Alarms

System shall have capability of on-line self-diagnosis. Any abnormal

conditions in subsystems shall be displayed as system alarm message onoperator console irrespective of the display selected.

2.4.4 Colour Dynamic Graphic Displays Formatted:Font: 14 pt, Font color: Black


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These are the graphic displays showing graphically the process pipes,equipment, and relevant instrumentation. Each display shall be organised in

order to show instrumentation for each process section and plant area.

The following information shall be availab le from these displays:

a) Measuring value of each analog variable

b) Status of pumps, on-off valves etc.c) Alarm either for ana log o r digital variables

Graphic displays shall be interactive type through which it shall be possible

to control the proc ess. It shall be possible to send motor start/ stop and

shutdown/ motorised valve open/ close commands from this display as perjob spec ifica tions.

It shall be possible to go from any graphic page to related graphic pages or

any group display or alarm summary in single key stroke using soft keyfunction.

The graphics will be built by the vendor on the basis of P & I diagrams whichwill be supp lied by R.C.F. It shall be possible to create new (custom) displays,

which can include graphics and animations.

Real time updating shall be possible for at least 125 data variables in eachdisplay. Dynamic updating shall include changing symbols (such as closed

valve symbol in place of open valve symbol and vice versa, changing levels

in vessels), change in colour, and change in values. The display ca ll up time

shall be less than 1 sec. for all dynamic graphic pa ges.

It shall be possible to create, modify, and delete the graphics through

interactive sessions on-line. The graphics modules shall enable creation ofstatic (plant schematics) and dynamics (process variables). Standard

building blocks / templates pertaining to a process industry like pipeline,valves, pumps etc. shall be provided and the user shall use these standard

blocks to create graphics without the help of any programming language. It

shall also be possible to add user defined symbols to the library of templates.

The current values of process variables with engineering units shall be

displayed in the objects. Abnormal conditions shall also be displayed in the

graphics. Once a picture has been built, it shall be possible to add to anyother picture/ pictures as sub picture. Scaling, scrolling and zooming of

graphics shall also be possible. Number of graphic pages available should

not be a limitation to adequately display the complete process.

2.4.5 Event Logging Formatted:Font: 14 pt, Font color: Black


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All event logs shall be displayable on any station and printed on separateAlarm/Event Printer.

System shall store every event, such as a point status change or an operator

ac tion, in an event journal. Events shall be collected period ically in an online

event database for queries and reporting.

Event archiving operation shall be performed at appropriate intervals. Systemshall archive events to a network fileserver or to disk as desired.

Events archived to a network fileserver can be copied to other media such asCD, or included in a system backup.

All changes in the system caused by, for example, alarms, operator actions,and changes in security level shall be logged as events. All alarms shall be

recorded in the event log, including when it was generated, when it returnedto normal, and when it was acknowledged.

On demand, a chronological record of events shall be displayed on any

station between user-specified time periods. The pages of the log shall be

scrolled and the log capable of being stopped at any time. It shall not befeasible for the operator to erase any part of the event log.

Alarm/Event Printer

System shall print a summary of alarms and events to an alarm/event printer

as and when desired.

2.4.6Report Generation

For analysing key system data, system shall provide a range of standardreports, including Alarm/Event reports for all alarms and events in a specified

time period. By using filters, this report shall provide an operator and/ or pointtrace fac ility.

It shall be possibleto design Excel-based Custom Reports, which can contain

almost any kind of information stored in the server database. User can eitherrequest reports when you required or schedule system to automatically

produce reports at pre-defined times. Outputs may be directed to screen,

separate report printeror file.

Following reports are required on demand as well as automatically at pre-set

time.

a) Shift/Daily/Monthly reports of different process variables.b) Hourly avg., hourly total, hourly max/min., instantaneous values of the

proc ess variables.

c) The shift/ daily/monthly report shall be printed automatica lly to



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repo rt printer at a specified time. But the On Demand reportshall be printed with demand from operator station.

d) Daily/Monthly reports showing raw material, utility consumption,

production, etc.

e) Energy consumption report for a section/ total plant.

f) Energy and mass balanc e and other analysis repo rts.g) System diagnostic reports in case of failure of any module /

component of the system both current and historical.h) Management Information Reports.

i) Log of operator initiated ac tions, on demand.j) Alarm and trip review reports.

The formats and other details of the various reports shall be designed inconsultation with the purchaser.

Apart from pre-formatted reports mentioned above, there shall be a report

writer with SQL-like commands to retrieve and generate reports in userdefinable formats. Number of reports should not be a limitation.

The reports shall have a configurable retention of generally 30 days andthese shall not be overwritten / scratched by the subsequent reports. There

shall be a spooling facility where the reports are preserved as spool files and

can be queued to the printer at a later stage.

There shall be facility for storage of above reports whenever required on a

disk, CD, or included in a system backup.

2.4.7Computation

The system shall have computational capabilities such as:

a) Pressure & temperature compensation for compressible fluidsb) Integration with the time (for flow measurement applica tion)c) Transformation into different engineering units.

d) Other standa rd c hemical engineering functions

e) User definable computations

These features are aimed towards fac ilitating the task of modifying the

process variables updated to the database.

2.4.8 Process Engineering Environment

It should be possible to change the functionality of the Operator Station toEngineering mode through password. The functionality of the Station shall be

logical and not physical.




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The environment for process engineering shall be largely menu-driven.Where developmental work is required to be done, involving programming

and analysis, the user-friendly environment shall be provided.

2.4.9 System Software

Standard software

The operating system of PLC based control system stations shall be based onWINDOWS only.

All programs required for control and data acquisition, unit operation, alarm

management, data communication and to define the system

configuration and display content shall be provided .

All the necessary utility programs, files and management tools necessary

to format the data of disk / CD, copy files from one source to another, deletefiles, list the directory of files, and view or print the da ta within a file shall

be provided.

The system hardware and software shall allow the users maintenance

staff to modify on-line the configuration, data grouping, descriptions, tag

numbers, alarm set points, and other display data as well as drawing ofprocess graphics as required.

Software for report generation, system diagnostics and self-documentationshall be provided

Vendor shall consider all the software functions available in system to ensurethat all the features / deliverables are available in each operator station.

Vendor shall provide detail list of software being offered with their license

quantity in their offer.

Each PLC based control system operator station shall have capability for

accessing any graphics/ report related to any area of the plant.

Documentation Software

Vendor shall provide documentation software that shall have a databasewhich updates itself from the System Database so as to provide complete

wiring details and I/O assignment details of a ll the PLC BASED CONTROL

SYSTEMtags.

It shall be possible to attach and view I/O sheets to any I/O tag name with

this software. Cross-reference facility shall be available so as to search anytag name of the system.


Formatted:Font: Bold, Font color: Black


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Import / export facility to MS excel, notepad , etc., shall be ava ilable in this

software.

Any change in tag name/ range/description/channel assignment shall be

automatically updated in this software.

OPC Interface: Vendor shall provide license and software facility for OPC

server (1no) and client (1no) along with necessary hardware required to

make OPC interface functional. Loading of CPU and server shall bedesigned so as to accommodate OPC server for any future third party

process optimisation on OPC interface.

2.5 ENGINEERING/OPERATORINGSTATIONWITH HMI , QTY. 1No.:

Engineering station shall be located in System room & not in local controlpanel.

Engineering Station shall also have licensed facility of HMI for process controlEngineering station make and model acceptable is only DELL make server

grade PC-12th generation, RAID-5 Configuration. Server grade operating

system -2012, RAM 8GB, HDD-500GB and dual redundant power supply with24 LED monitor.

Engineering station shall have all the features and capabilities of operator

stationoperator stationas mentioned above. In addition it shall also haveother capabilities as mentioned below,

a) EngineeringTools :Tools:

i.The tools fac ilitate on-line and off-line Engineering functions of thesystem.

ii.Engineering tools to build graphic and database shall be available ona standa rd environment viz. Windows operating system.

iii.Graphics /Database tools shall comprise of easy use of GUI Icons /Menus

b) Ooperator station shall be a lso licenced for engineering capabilitiesc) Auxiliary drive shall be available for system software loading and taking

backups.

d) Other specifications shall be same as for operator station.e) Engineering licence shall be available for all the tags.f) It shall be possible to all engineering functions online without shutdown

/ downloading of any controller or station.

2.6 OPERATOR STATION UPDATE TIME

Formatted:Font: Bold, Font color: Black




Formatted:Font: Bold, Underline, Font color: Black




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System shall guarantee the following update times :

a) Display page call up time: Less than 1 sec for non graphic pages.

b) Graphic page call up time: Less than 1 sec for a page with less than

50 live points.

c) Page refresh time: Live points in the actually displayeddisplayedpageshall

be refreshed every second (50 live points approx.)d) Issue of commands: less than 2 sec from station to field including

feedback.

2.7 SYSTEM SECURITY

The following three levels of security shall be provided by the system :

a) Operator level

b) Proc ess engineer levelc) Engineering level

The type of security a t the Operator Station & Engineering station shall be

password type.

START menu & exit/+/- buttons of Station window shall be non operable &hidden from screen. Operator shall not be able to access any of Windows

utilities whenever locked.

The system shall be designed in a way that minimises the possibility o f ahardware or software failure.

Consequently, in the event of failure, effective diagnostics and error

messages shall be provided to facilitate detection and resolution of the

failure. The vendor based on his knowledge of his equipment, shall provideadditional on-line diagnostics and checks in addition to those in thespecification.

In case of any mal-operation it should be possible to identify from whichstaion the operator ac tion took place.

2.8.1 Power Failure / Auto Restart

a) When power is restored a fter power failure, the C ONTROL SYSTEM shallreboot automatically

b) The stations, controllers and process interface units shall have




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power-fail detection. Upon power failure, the hardware/softwareshall perform the necessary functions to bring the appropriate

equipment to an orderly shutdown, including an orderly deactivation

of a ll the processing.

c) When data acquisition units and controllers lose power, it shall

annunciate on CONTROL SYSTEM and logged along with the time ofoccurrence.

2.8.2 Memory Protection

The system shall be protected from being overwritten. The system software

shall also be capable of protecting itself to ensure integrity. The memories

shall have parity check and detection.

2.8.3 File and Data Security

All data communications shall have adequate error checking, detecting,reporting and recovery features. The failure of data highway shall be

displayed on the alarm summary display at the station and also logged onprinters.

2.8.4 Process Input-Output Checks

Every sampled analog value shall be checked against pre-set and low

sensor reasonab ility limits. If a limit is detected, it shall be flagged and

alarmed and appropriate quality coding indication is provided as part of

the database. It shall be possible to disable the actual alarm condition

knowingly.

The system shall provide automatic open circuit detec tion of thethermocouple open circuit cond itions. Open circuit detection shall not

affect the accuracy of a temperature more than 0.25C.

There shall be check on the analog signal input to determine if it is within

the range of the analog - to digital converter.

For alarm purposes, it shall be possible to define burn out up-scale or down-

sca le values.

2.9 DATA BASE MANAGEMENT AND DATA BASE

The plant historical database shall be designed to store a t least one-month

data of productions, consumption, critical variables on hourly basis, as well






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as other standard data elements. It shall be possible to retrieve the data inthe form of reports / files as defined by the user.

Sufficient integrity features shall be provided to protect the data-base from

ca tastrophic failures and corruption.

The supplier shall provide facility for archiving of the operational data-base.

The archive shall be such as to provide a backup of historica l data on acontinuous basis for very long periods.

The vendor shall make available the structure and organisation of database

to the purchaser. The database shall be global and provide logical inde-

pendence from the physical configuration.

The vendor shall provide a full and comprehensive database operationsprocedure for backups, reports generation, graphics operation, data-

protection, securities etc.

2.10 ON-LINE HELP

An on-line help facility shall be provided at the console, which shall provide

the user information about the following:

a) System configuration and details.

b) Maintenance manuals/procedures.

c) Software a nd software features.d) Proc ess manual including P&I diagrams.

System shall have its own documentation so that engineers may not carrymanuals to rectify the fault.


Formatted:Font: 14 pt, No underline, Font color: Black


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CHAPTER III

CONFIGURATION AND TECHNICAL

SPECIFICATIONS


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3. CONFIGURATION AND TECHNICAL SPECIFICATIONS

3.1 OVERALL CONFIGURATION

The configuration of the system shall be such as to provide a plant networkwith modules for Operator / Engineering Stations, Controllers, input/output,

Historic database, etc. The main data highway shall provide peer to peer

communication between the modules.

All communication shall be dual redundant.

The configuration schematic shall be furnished.

Client-Server architecture is not acceptable. All three stations shall have

direct access to PLC based control systemcontrollers.

In view of keeping low cost & at the same time ensuring high reliability, RCF

has not asked for any SIL 3 /TUV certified/ TMR /Quadlog PLC. PLC cards shallbe only provided in redundant configuration as specified in 2.1earlier. Eventhough, vendors can offer high end products as a standard feature ,any

additional features regarding redundancy/safety which are not asked in NIT

shall be responsibility of vendor in view of high cost.

The PLC based control system shall be predominantly software driven where

functionality and personality of the devices shall be definable at the logicallevel rather than through physical interconnection of the devices.

3.2 COMMUNICATIONData Transmission Rate: Capable of high speed data transfers over

redundant Ethernet in the range of 100 MB/sec . Ethernet shall havecapabilities to detect & self-rectify faults for undeterred communication to

various intermediate nodes on network. The system network shall have aProtocol & industry standard. The main highway shall be preferably MAP / IEEE

802.4 compliant.

Communication between control system and operating station(2 nos)(located in remotely located control panel) shall be distributed among thedistance of 50 meters. The communication should be redundant. Vendor shall

quote suitable media & furnish requirements for laying Ethernet cable to havesecured communica tion. C ost of ca ble laying/ installation o f infrastructuresuch as tray work etc. shall be in scope of vendo r in view of expertise and one

point responsibility.


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3.2.1Internal Communications

It shall be possible for the vendors standa rd communications networks to befully redundant with automatic switch over. It shall be possible to monitor the

status and active communication path at any time.

Failure of one of the redundant cables shall not degrade system

performance.

Communications error checking techniques shall be incorporated so that the

probability of an undetected single bit error occurring is one in 100 million.

Communications system configured as redundant shall either use the backuppath continuously or check the backup path at least once per minute to

determine if it is operating normally.

ETHERNET shall be extended on dual redundant Fibre optic cable up to a

distance of 250 mtrs.(Total length for dual redundant cable shall be 500 mtrs.)Which shall have total 5 nodes for connection of operating/engineering

stations & one remote DI/DO rack. Stations shall be connected to any of the

nodes up to 250 mtrs. Lengths. Ethernet switch shall be placed in System

marshalling cabinets located in Methylamine plant.

Failure or planned shutdown of any one device connected to the

communications network shall not affect the ability of the system tocommunicate with any other device on the network.

3.3 CONTROLLER SUB-SYSTEM:

The necessary hardware like I/O cards, processors, electronics etc. for thesuccessful control of process shall be quoted as required for meeting

specifications and achieving functionality mentioned in the NIT.

The loading sheet indicating the distribution of c ontroller and I/O cards forthe specified I/O counts shall be furnished.

QUANTITY : AS REQUIRED FOR I/O CO UNTS.

3.4 OPERATOR STATION(2 Nos.)/ENGINEERING STATION(1No.)

All Operator / Engineering station computers shall be DELL make workstationgrade with latest configuration and with 24 LED monitor.

Each 24LED console shall have its own individual station elec tronics i.e. each





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LED station shall be a node on the main highway.

a) Hi-resolution graphics/text monitors

b) Mouse shall be provided as cursor pointing device.

c) All console shall be with standard QUERTY keyboard.

d) Each Keyboard shall have a set of dual function user configurablekeys. These keys shall be configured to access important pages in

single key stroke.e) Set point/ Output tolerance check- If Set point of a controller and its

output in manual mode is changed by 10% or more than its previous

value system shall have facility to warn the operator and ask forconfirmation for such change and shall be software configurable.

f) Eac h operator / Engg. Station shall have an acc ess to global database.

g) Operator shall not have the fac ility to exceed the predefined Set-pointHI and set-point LO (tagwisetag wise). This security shall be available

tagwisetag wiseand shall be configurable.h) Any single point failure shall not stop the plant operation and offered

system shall have true redundancy to overcome this.

i) Furniture: Furniture required for operator station shall be included in theoffer. It shall be of Pyrotech make and of best quality. Individual

metallic cabinet per operator/engineering station with heat dissipation

fans wthwith conveniently bigger space for CPU shall be ava ilableinside the enclosure.

Station Failure Security

Failure or disconnection of a station shall not affec t the operation of any other

device on the communication system.

Main Electrical switch

The main electrical power switch shall be provided. A receptac le with abreaker shall be provided for maintenance work.

Internal wiring

Incoming and out going cable /wires to or from to or from the panel, or both,

shall terminate at the terminals mounted in the panel. All internal wiring after

terminals shall be completed by the PLC BASED CONTROL SYSTEM vendor.

Grounding

As a minimum, safety grounding and signal grounding shall be provided witha grounding strip.

Wire identification


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Wire identification shall be provided with the same numbering system as thePLC based control system.

Spares

Switch with fuse for power supply : 20%Terminals : 20%

Miniature circuit breaker for each instrument : 20%Name plate with tag number

3.5 REPORTS AND PRINTERS

This section details the general requirements for system reporting functions

and reporting printers.

Report Package:

a. The contrac tor shall provide utility packages of application programmes

to generate report formats using a conversational, fill-in-the blank

approach.

b) Software programming shall not be required to generate reports.c) It shall be possible to use any variable in the system in a report.

d) It shall be possible to activate report on the following bases:

i.On demand (operator's request)ii.Shift, daily and monthlyiii.Event driven

e) It shall be possible for all reports to be displayed on a station screen as

well as printed on a report printer.

f) Reports to the same device are to be queued.g) It shall be possible to configure a User Defined report to acc ept

manually entered data for specified fields.

Report Printers:

Printers used for report generation shall be dedicated for printing reports only.

Printer shall be B/W Network LaserJet printer of HP make. Vendor shall specifyoffered make & model.

Alarm and Event Printer

Printer shall be Colour Network LaserJet printer of HP make. Vendor shall

specify offered make & model.


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- Print out shall show as a minimum the date, description, date andtime of occ urrence, time of acknowledgment, time of return to

normal.

- Event logging suchlogging suchas operator ac tions.

- Printer shall be provided with cover and furniture for installation.

3.6 STORAGE DEVICES

a) USB hard disk of size 500 GB for data backup.b) RAID 5 configurationconfigurationsHard Disk: Storage capacity as re-quired but not

less than 320 GB . GB. If higher capacity is required same may be

offered.

c) DVD R/W drive: Requiredd) Main memory RAM : Not less than 2 GB .

e) CPU : 32/64 bit

3.7 MISCELLANEOUS

Necessary cabinets, interconnecting cables between controllers, I/O

modules, marshalingmarshallingracks, etc.to all their sub-systems, consolemounts and furniture, etc. shall be provided by vendor as per specifications

mentioned in the NIT.

Inter connection cables:cables:

a) cCables for analog I/O : 0.5 mm2 stranded tinnedb) Power supply cable : 2.5mm2, 3 core solid conductors, PVC

sheathed, Size of the conductor as required.

c) Digital output ca ble : 1.5 mm2 stranded tinned copper, PVCInsulated, PVC sheathed.

3.8 SYSTEM INTEGRITY FEATURES

The system shall have inherent integrity to prevent damage to equipment or

adverse effects on the process arising out of system or component failures.

These features shall be explained in the offer.

3.9 CABINETS

General Requirements


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The cabinets comprising of following shall be provided for the controlsystem:-

a) Relay: Relays with base shall be individual pluggable type (Omron

/Pheonix /Paramount /Paramountmake only)with minimum 2NO/2NC

contac ts of contact rating 5A, 110VDC and 5A, 230VAC .

b) Mounting of Controllers, I/O cards and other system components.c) Power distribution :to house switches, step down transformer for 24 VDC

supplies and circuit breakers for electric power supply for PLC basedcontrol system and power supplies etc.

d) Annunciator/pump operation panel: with Pump remote/local &

start/stop buttons. Also provision of emergency plant trip button.All of the DI & Dos on this cabinet shall be connected to system

through Remote I/O on Ethernet.

Type and construction

All cabinets shall be o f M/s Pyrotech /M/ s Rittal make only.

Cabinet's framework shall be provided and standardised in accordance tothe following:

a) Dimensions/appea rance and colour in accordance with system

cabinets: Vendor to specifyb) Frameworks: Self-standing type, min. 2.3 mm thick CRCA steel

plates, with channel base

c) Painting cycle :In accordance to Mfr. STD - Colours to be defined in

P.O.

d) Cables entry - From the bottom

e) Cabinet access - From rear & from front with locked doors completewith keys.

f) Copper grounding bars. As a minimum, safety grounding and signalgrounding shall be provided with a grounding strip.

g) Terminals-Weid Mueller / phoenixh) Cables fixing through cable glands of SS 304 material.

i) Service power socket with 240 V 50 Hz 500 Watt and 110 V AC .

j) Forced Ventilation from top of the ca binets is required for all thecabinets.

k) Internal Light: Duplex fluorescent type complete with switch (on/off)

240 V, 50 Hz.

l) Incoming and out going cables/wires from and to the cab inets shallterminate at terminals in the cab inets. All these internal wiring,

termination and interconnection between cabinets, PLC BASED

CONTROL SYSTEM ca binets and panels shall be executed by Vendor.m) Wire identification shall be provided with the same numbering

system as the PLC based control system.

n) Reference standard -CENELEC or equivalent Indian/ Internationallyrecognised std. valid in India.

o) Cable ducts - Dedicated for power, IS signal and non-IS signals. Cable

Formatted:Indent: Left: 1.5 cm, No bullets or numbering,

Tab stops: Not at 1.5 cm


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ducts shall be of plastic with cover (150 mm) sized to allow load ingcoefficient of 80%.

p) Execution: IP 50 or better, these shall withstand environmental

conditions specified elsewhere.

q) Spare terminals : Min. 25%

r) Spa re switch with fuse for power supply : 20%s) Lifting eye bolts (4 Nos. per cabinet) required.

3.9.1 MARSHALING CABINET

Field cable termination marshalling cabinet shall be comprising of

termination of external field wiring and the system cables for the PLC basedcontrol system.

3.9.2 POWER DISTRIBUTION CABINET

Purpose of such cabinet is to allow power distribution from UPS (115 V 50 Hz)

to PLC based control system cabinets, aux. cabinets. Cab inet will beorganised in standa rd modules such as 110 VAC UPS supplies,230 VAC utilitysuppies,24 VDC. Each module will allow the plac ing of 10 feeders each one

consisting o f 10 MCB. Each cab inet is rated for standard modules. MC B shall

be double pole type.It shall be designed according to the following requirements.

a) Type and construction shall be as per 3.10.2

b) A proper protec ting cover shall be provided at the terminalsc) Main isolating switches for each primary supply by others shall be

provided.d) Miniature Circuit Breaker (MCB) for all equipment,toequipment, toPLC

based control

system, peripherals, the panels, etc .e) Rating and Set of trip of MCB shall be decided by the vendor

withvendor withdue

consideration of max. load, inrush current and heat dispersion.

f) 10 % spare MCB to be provided.g) A 110VAC to 230 VAC is to be provided for 230VAC application and in

each cab inet 230VAC service socket with switch is to be provided. In

PDC individual MCB to be provided for each cab inet 230 VAC power

supply.

h) Name plates showing tag number or equipment number for each MCB.

i) 1 One Digital Ammeter with fuse and 4-20mA analog output, CToperatedand One & 1Digital Voltmeter

with fuseand 4-20mA analog output and 1 Digital Frequency meterwith fuse.

j) and 4-20mA analog output. All these analog outputs shall beconnected to the system as inputs.

k)j) 1Power on lamp indication


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l)k) cooling fanm)l) Fuse rating shall be decided during detailed Engg.

n)m)Incoming cables shall be terminated on dedicated bus bar from which

individual circuit shall tap the power. No looping of any kind is

permitted. Isolation for each circuit shall be through two pole MCB.

o)n) Wiring by solid copper conductor cable with 1100v grade PVCinsulation. Cable conductor sizes shall be as per feeder rating.

p)o)Terminals shall be of PVC and type, Weid Mueller/phoenix make, DIN railmounted. All open type terminals with phase barriers. Terminal sizes shall

be as per current rating.

3.9.3 AUXILIARY CABINETPrewired Solid state annunc iator(Minilec make only) with 32 windows having

LED lamps with pump start/stop/ remote-local buttons shall be provided in

standa rd auxiliary cabinet as per previous specifications for MOC & COLOR.Motor start/stop/ remote/ loca l buttons shall be well known make two position

type switch. Emergency stop button shall be p rotec ted by plastic cover.There shall be provision of installing small instruments such as turbine speed

monitor transmitter/3300 vibration monitor on top o f the annunciator housing.

Such instrument housing shall be protected by plastic cover to avoid entry of

Hazardous gas. If required the vibration monitor 3300 will be installed in thecabinet and it will be communicated to the control system through

RS232/RS485. This will be dec ided during deta il engineering. However vendor

has to consider one communication card for the vibration system interfacewith the control system.

Auxillary cabinet shall be positively purged with Instrument Air to avoid anyGas entry. Minimum IP 55 protection is required.

Vendor shall discuss with plant Instrumentation personnel before submittingoffer to understand concept. There are total 10 Remote/local and

Start/stop buttons on the cabinet.

LED cluster type pushbuttons shall be provided wherever required.

On screen annunciator is not acceptable. Details of Annunciator windows

shall be provided during data handover to vendor.

Vendor shall provide electric hooter (with adjustable sound & tone). Hooter

shall be configured to give audible alarm whenever any process or system

alarm, annunciation occurs. Configuration of audible alarm shall beresponsibility of vendor. Requirement of any additional DI / DO shall be

specified.

Vendor shall provide push button for emergency plant tripping.


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3.10 SYSTEM POWER SUPPLY AND EARTHING/SHIELDINGDETAILS

3.10.1 Power Supply

The power supply for the entire system will be provided by the purchaser froman uninterrupted/stabilized power supply ofsupply of 115V 10% (50 Hz

3%)at) at one point as single phase supply with neutral connected toground. Where other voltages are needed, for instance 24 V DC. etc., thismust be generated by power supply units which will be within the scope of

supply of the system supply. These SMPS should be of Digitronics or Phoenix

make only with diode O-ring unit. The manufacturer shall ensure complete

redundancy (hot standby type)&)and distribution in power supply of differentsub systems like I/Omodule/ controller cabinetracks,24LED monitor, other

hardware units etc. Complete power supply distribution shall be through

minimum 4 power supplies with capability to supply 40%of normal supplycurrent.so that in the event of failure of one power supply other power

supplies can keep power uninterrupted. Power shall be distributed amongstthree phases of 110 VAC UPS.Also current drawn by each power supply shall

be indicated. Whenever any power supply fails, the status of the same shallbe updated on System Status Alarms summary with an audible alarm. All

redundant power supplies shall be wired so as to be truly redundant and shall

draw supply from separate sources. In case of failure of any one supply

source the power to the system shall be available from the redundant source

and the redundant power supply. Load shall be equally distributed on theredundant power supply distribution.

Vendor shall provide a power distribution cabinet to which the purchaser shall

supply the bulk power as mentioned above. The d istribution cabinet shall alsoinclude an isolation transformer.

All further distribution including cabling to each cabinet are included in the

vendors scope of supply. It is desired that each card/ instrument (smallestconsumer) be provided with a separate switch/ fuse unit with a common MCB

for each cabinet. This shall ensure that as far as possible fault in any of minorcomponents shall be isolated at that level itself instead of affecting other

connected boards.

Vendor shall also include in their scope power supply and cabling forauxiliary devices like annunciators, printers plotters, Winchester drives etc .

Total CUMULATIVE current load for solenoid valves shall be 1 A for 24 VDC &

1A for 110 VAC in the existing system.

Vendor shall furnish following details related to power supply:

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