DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
SPECIFICATIONS FOR
DCS
Page 1 of 124
DISTRIBUTED CONTROL SYSTEM (DCS)/
PROCESS CONTROL SYSTEM (PCS)
SPECIFICATION
For
DAROU-1 SULHURIC ACID PLANT AND ITS
UTILITY
ICS INDORAMA
SENEGAL – WEST AFRICA
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DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
SPECIFICATIONS FOR
DCS
Page 2 of 124
INDEX
SR. NO.
TOPIC
1.0
Scope
2.0
ABBREVIATIONS Used in this document
3.0
Control and Safeguarding Systems Objectives
4.0
Control and Operation philosophy
5.0
EQUIPMENT LOCATIONS
6.0
SYSTEMS INTEGRATION /FORIGEN INTERFACE
7.0
FIELD INTERFACE
8.0
POWER SUPPLY
9.0
ALARM MANAGEMENT
10.0
CONTROL AND SAFEGUARDING DESIGN CRITERIA
11.0
DCS DESIGN CRITERIA
12.0
SYSTEM OVERVIEW
13.0
FUNCTIONAL SPECIFICATIONS
14.0
BOUGHT OUT ITEMS INCLUDED IN VENDOR’S SCOPE OF
SUPPLY
15.0
INSPECTION
16.0
TEST SET-UP REQUIREMENTS
17.0
INSTALLATION PRE-COMMISSIONING AND COMMISSIONING
18.0
FINAL ACCEPTANCE AND WARRANTY
19.0
TRAINING
20.0
SPARES PHILOSOPHY AND CONSUMABLES
21.0
INFORMATION REQUIRED WITH THE BID
22.0
DOCUMENTATION REQUIREMENTS
ANNEXURE-I
IO LIST
ANNEXURE-II
I/O LIST AND BOM QUOTED BY DIFFERENT VENDORS
ANNEXURE-III
APPLICABLE HARDWARE UNIT RATES FOR ADDITION /
DELETION
ANNEXURE-IV
BIDDER to fill in the complete form for technical comparison purpose
ANNEXURE-V
ARCHITECTURE
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DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
SPECIFICATIONS FOR
DCS
Page 3 of 124
1. Scope
This specification outlines the instrument control philosophy of the complete
Project. Covered by this specification are the DCS system and their interfaces
to other systems. This philosophy is not intended as a technical specification
and is restricted to the description of the overall philosophy; detailed technical
requirements are not specified. For detailed specifications, refer other sections
of these documents.
DAROU-1 SULPHURIC ACID PLNAT AND ITS UTILIITY Regulation Upgradation project involves:
1.1. Replacement of standalone electronic controllers/Recorders/Indicators with
DCS System.
1.2. Replacement of Relay based trip interlock with DCS system.
1.3. Integration of DCS, field instrumentation and sub-systems shall be done at
site by DCS vendors.
1.4. DCS system shall be installed in existing control room of Darou-1
1.5. Following specific sub-systems shall be integrated with DCS
1.5.1.
Sulphuric acid plant (SAP-1)
1.5.1.1. Voith Speed Governing system for Tubro Blower. The
system includes one Voith TurCon DTc Steam Turbine Controller
along with its local Operating Control panel. Local panel is
installed in Darou-1 Controller Room. The governor shall be
integrated with DCS using Modbus TCP connectivity which is
provided in Voith TurCon DTc controller.
The DCS will have face faceplate of the governor to issue remote
commands to Voith TurCon DTc controller for speed control.
Trip contacts of Voith TurCon DTc controller shall be hard wired
with DCS system.
1.5.1.2. Vibration monitoring system of Turbo Blower – Sarayu
Condition Monitoring System VMS-3000.
The VMS is installed in governor controller Panel. 4~20mA
signals for individual channels will be hard wired to DCS.
Trip contacts from VMS shall be hard wired with DCS system.
The system will be integrated with DCS through RS-485 link
(MODBUS RTU protocol) also, provided in the VMS, for display
of all parameter on DCS.
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1.5.1.3. Acid Coolers Anodic Protection –Anodic protection System
Consist of a controller module.
The system will be integrated with DCS through 485 link
(MODBUS RTU protocol) also, provided in the Anodic protection
Controller, for display of all parameter on DCS.
1.5.2. UTILITY-1
1.5.2.1. Woodward Speed Governing system For TAP (Tubro
Alternator Primary). The system includes one 505E Controller
along with its local Operating Control panel. Local panel is
installed in DAROU-1 Control Room. The governor shall be
integrated with DCS using RS-485 connectivity which is provided
in Woodward 505E controller.
The DCS will have face faceplate of the governor to issue remote
commands to Woodward 505 E controller for speed control and
extraction pressure control.
Trip contacts from 505E controller shall be hard wired with DCS
system.
1.5.2.2. Vibration monitoring system For TAP – Bently Nevada
make.
The VMS is installed in governor controller Panel. 4~20mA
signals for individual channels will be hard wired to DCS.
Trip contacts from VMS shall be hard wired with DCS system.
The system will be integrated with DCS through RS-485 link
(MODBUS RTU protocol) also, provided in the VMS, for display
of all parameter on DCS.
1.5.2.3. Governing
Secondary).
system
For
TAS
(Tubro
Alternator
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SPECIFICATIONS FOR
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Presently there is no electronic Governing system for TAS. But In
future this going to be migrated to electronic system.
So following this need to considered. The governor shall be
integrated with DCS using RS-485 connectivity (Modbus RTU)
OR ModBus TCP. Both provisions need to be considered.
The DCS will have face faceplate of the governor to issue remote
commands to governor for speed control and extraction pressure
control.
Trip contacts from governor shall be hard wired with DCS system.
1.5.2.4. Vibration monitoring system For TAS – Presently there is
no VMS.
4~20mA signals for individual channels will be hard wired to DCS.
Trip contacts from VMS shall be hard wired with DCS system.
The system will be integrated with DCS through RS-485 link
(MODBUS RTU protocol) also, provided in the VMS, for display
of all parameter on DCS. Modbus TCP need to be considered.
1.5.2.5. Instrument Air Compressor Controller- 4 nos
The system will be integrated with DCS through RS-485 link
(MODBUS RTU protocol) also, provided in the VMS, for display
of all parameter on DCS. Modbus TCP need to be considered.
1.5.2.6. Electrical System:
For Numerical Relay, Generator Controller etc. 10 nos. of
RS-485 (Modbus RTU) and 15 Nos of Modbus TCP
connection need to be considered.
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SPECIFICATIONS FOR
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NOTE:
2 Nos of Profibus DP cards needs to be consider for Each FCS/DCS
Controller.
For every RS-485 Modbus RTU , Modbus TCP need to considered while
design the system.
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SPECIFICATIONS FOR
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1.6. SCOPE OF WORK
1.6.1.
DCS Vendor:
Design, Engineering (including making logics and control schemes as per
owner’s drawings and incorporating the same in DCS), Supply, Installation
and commissioning of :
1.6.1.1.
DCS System including operator consoles, remote
consoles, engineering workstation, printers, PDB for Field
Instruments and Control panels, Current Transducer Penal,
Isolators as per details specifications as per annexure.
1.6.1.2.
Design, engineering, and incorporation of control
schemes in DCS, Coordination with vendors for seamless
integration of DCS and various sub-systems as specified
elsewhere in the document.
1.6.1.3.
Establishing communication with third party systems
and demonstrating the same during FAT.
1.6.1.4.
Generation of logging reports and other management
information reports
1.6.1.5.
Preparation of loop drawings as per formats finalized
1.6.1.6.
Preparation of all drawings / documents required for
engineering, review / approval
1.6.1.7.
Preparation of all as-built drawings
1.6.1.8.
Isolator panel cabinet complete with isolators, prewired and marked terminal strips, redundant power supply,
cooling fans
1.6.1.9.
Electrical interface cabinets along with associated
hardware/modules/relays
1.6.1.10. Auxiliary console complete with annunciator, Push
buttons, led lamps, Reset switches.
1.6.1.11.
Supply of SS conduits for communication cables
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1.6.1.12. Supply of other erection hardware and consumables
like cable glands, ferrules, lugs, etc. as required for cables
supplied by vendor
1.6.1.13. Supply of furniture like consoles, chairs, furniture for
peripherals etc.
1.6.1.14. Packing and forwarding of all items included in scope
of supply
1.6.1.15.
Pyrotech workspace/rittal make furniture for work
stations/PCs including chairs for operators for control room and
engineering room.
1.6.1.16.
Master GPS clock need to consider for Time Synchronization.
DCS, all sub systems, electrical systems need to be synchronized
with Master GPS Clock. Accuracy must be within 1 ms.
1.6.1.17. Commissioning of DCS system in association with Sub
System vendor for seamless integration of both the
systems.
1.6.1.18.
Pre-Factory Acceptance Test (Pre-FAT)
1.6.1.19.
Integrated Factory Acceptance Test (IFAT)
1.6.1.20. Packing and forwarding of all items included in scope
of supply
1.6.1.21. Transport to site of all items included in scope of
supply.
1.6.1.22. Supply of commissioning spares, two years spares,
consumables
1.6.1.23. Laying, termination, jointing of FO cables, incl. OTDR
testing.
1.6.1.24. System power up, loading of configuration, application
software
1.6.1.25. Internal loop / logic and interlock checking from
marshalling racks up to operator stations.
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DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
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SPECIFICATIONS FOR
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1.6.1.26.
Integrated Site Acceptance Test (SAT)
1.6.1.27.
Providing commissioning assistance
1.6.1.28.
Documentation
1.6.1.29.
Training for operation and maintenance staff.
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1.6.1.30. Comprehensive AMC (without resident engineer) for
five years after expiry of the warranty period with minimum
five visits (including emergency & periodic visits) of the
service engineer per year. The AMC shall include supply,
replacement / repairs of all the system modules / cards etc.
All the software problems / up gradations shall have to be
taken care of by the vendor
NOTE:
Installation and Commissioning job will be carried out tentatively in
Annual Shutdown.
Approximately 30 days shutdown will be available to carry out the total
job. However, installation work may be carried out beforehand in running
plant wherever possible.
2. ABBREVIATIONS Used in this document:
CPU
DCS
ESD
HMI
MCC
CCR
MOS
POS
MS
OPC OLE
PLC
SER
TÜV
VDU
=
Central Processing Unit
=
Distributed Control System
=
Emergency Shutdown System
=
Human Machine Interface
=
Motor Control Centre
=
Central Control Room
=
Maintenance Override Switch
=
Position/operation override switch
=
Microsoft
=
(Object Linking and Embedding) for Process Control
=
Programmable Logic Controller
=
Sequence of Events Recorder
=
Technische Überwachsungs Verein
= Video Display Unit ( Always 21” square model or 24” wide
screen TFT /LCD type colour monitor)
3. Control and Safeguarding Systems Objectives:
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SPECIFICATIONS FOR
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The main objective of the plant and its control system is to, safely and reliably,
continuously produce on-specification product. Without compromising these
objectives, the control systems shall also be designed to maximize plant
availability, minimize plant energy consumption, adverse environmental impact
and requirements for operator interventions. The principal objective of the
safeguarding systems is the protection of personnel, environment, plant and
equipment and the maintenance of safe operating conditions compatible with
production requirements.
This shall result in control and safeguarding system design that is:
- Safe
- Simple to maintain
- Simple to operate
- Flexible to accommodate changes in technology and operating
requirements
- Flexible to provide for expansion during 20 years design life – Reliable
4. Control and Operation philosophy:
4.1.
This project comprises of following unit for which there shall be Common
DCS system for all controls & interlocks with Redundant Fault Tolerance
Controller/FCS for individual units:
4.1.1.
4.1.2.
4.1.3.
4.1.4.
4.1.5.
SAP-1 (Sulphuric acid plant-1).
TAP (Turbo Alternator Primary)
TAS (Turbo Alternator Secondary)
DM Plant
Common Section (Air Compressor, Air Dryer etc.)
4.2.
All existing plant facilities (as mentioned above in Sr no 4.1) are
currently using pneumatic control system & single/Dual loop electronic
controller located in Existing control room. All these instrumentation controls &
interlocks will now be implemented in New DCS system as elaborated further
in this document.
4.3.
All process and utility units and related facilities for the entire plant
shall be monitored and controlled from the Central DCS located at Central
Control Room. Every major and minor unit of the plant shall be operated
independently from dedicated console, consisting of DCS operator interfaces.
All of these VDU’s shall be 24” wide screen LED type monitor only.
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4.4.
The DCS operator interface (VDU based) shall be the primary
integrated window for operation of the control and safeguarding systems and
shall provide access to:
4.4.1.
4.4.2.
4.4.3.
4.4.4.
4.4.5.
4.4.6.
4.4.7.
4.4.8.
4.5.
Process control
Sequence control status
Equipment status
Alarm overview
Trip status overview
Historical data trending
Generation of dynamic graphics as per process requirement
Machine Monitoring
All control and interlocks shall be monitored, controlled, and
engineered through work stations as given below
4.5.1.
Five operator stations. (5 in CCR and 1 in shift in-charge
room) Consoles to be placed in the CCR will be Double tier type.
4.5.2.
ONE Engineering stations.
4.5.3.
One 72” wall mountable type console for process overview in
CCR
4.5.4.
4.6.
One dedicated PC for reports generated by DCS.
All consoles for DCS shall be supplied with 24” wide screen LED type
colour monitors.
4.7.
All controls and interlocks of the complete plant, shall be
performed / realized in the central DCS only.
4.8.
Comprehensive facilities are to be provided to ensure that the
operators at all times have complete overview of the plant status from the HMI.
Information will be presented in the form of ‘live’ graphic displays and simulated
instrument faceplates. The system shall be configured to permit the operator to
determine the cause of an alarm with a minimum of keystrokes at the console,
without having to memorise tag numbers, so that a rapid reaction to an
abnormal situation can be achieved.
5. EQUIPMENT LOCATIONS
5.1.
All DCS operator stations, auxiliary hardwired console shall be
located in central control room of DAROU-1.
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5.2.
All DCS marshalling cabinets, System hardware cabinets, etc. shall
be located in central cabinet room of DAROU-1.
5.3.
Existing subsystems such as Bently Nevada Vibration Monitoring
system, Woodward Governor system, Anti-surge control system for the turbo
machinery etc. system’s secondary hardware shall also be located in central
cabinet room.
5.4.
DCS engineering stations, all other programming PC/Engineering
station of other type control systems, etc. shall be located in central
engineering room which will be in the close vicinity of central cabinet room
and central control room.
5.5.
All IRC (Interposing Relay Cabinets or Digital Interface cabinet) and
IFC (Interface cabinet or simply Analog Interface Cabinet) between Electrical
and Instruments shall be located in central cabinet room only. However Current
transducer panel and isolator for analog signals from electrical motor currents
will be placed in electrical sub-station.
5.6.
All DCS and other control systems’ Panel shall be openable from
front and back side. The relevant DCS hardware shall be installed in dedicated
panels. The panel make/model/size is specified in detail specification of DCS.
There shall be panel segregation for various I/Os meant for DCS. Also, there
shall be panel segregation for diff. type of I/Os for DCS, other control systems.
This means that analog input and analog output shall be accommodated in a
separate marshalling panel/DCS panel. Digital input and interposing shall be
accommodated in a separate marshalling/DCS panel. Digital output and all
interposing relays shall be accommodated in separate panels.
6. SYSTEMS INTEGRATION /FORIGEN INTERFACE
6.1. The vendors of DCS and Sub systems shall engineer the systems as one
integrated control and safeguarding system with respect to operator
presentation. The systems shall be brought ready for integration at site. DCS
and sub system vendors will list out and share various requirements such as
I/O’s communication ports etc for seamless integration of DCS and sub
systems at site. The DCS HMI shall be the single operating window for
integrated control and safeguarding system. Communications of the sub
systems with the DCS shall be accomplished via dedicated redundant, single
fault tolerant links.
6.2. An Open Control Systems Network shall allow the integrated control and
safeguarding system to communicate with third party control systems,
auxiliary information systems and higher-level automation systems utilizing
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OPC connectivity standards. Although APC is not envisaged immediately,
The DCS shall have the capability to be seamlessly integrated with an APC
whenever required. Special attention shall be given to network security of the
Open Control Systems Network. Firewall shall prevent unauthorized access
from the office network to the Open Control Systems Network.
6.3. Communication with Plant Network System: The operators shall be able to
access entire Plant Information network through the operator consoles. A
gateway from the DCS data highway and the Ethernet LAN shall be provided,
to allow the Plant Information System to exchange data. Layer 3 switch with
firewall to be provided.
This Plant network information system shall collect data from DCS for data
validation, history management, advanced process control, material
balances.
6.4. It shall be possible to connect with the integrated control and safeguarding
system with redundant OPC servers.
6.5. DCS vendor will supply All IRC (Interposing Relay Cabinets or Digital
Interface cabinet) and IFC (Interface cabinet or simply Analog Interface
Cabinet) between Electrical and Instruments. These shall be located in
central cabinet room only.
6.6. All the necessary hardware required shall be considered. Hardware firewall
between PLANT INFORMATION/HISTORIAN server and DCS OPC server
must be provided.
6.7. Hardware and Software/Licence Required to communication with other DCS
System need be consider. Both Read & write accessibility required.
6.8. However, isolator panel for analog signals from electrical motor currents will
be placed in electrical sub-station. Electrical analog signals are available in
electrical sub-station. DCS vendor will supply Electrical interface cabinets
along with associated hardware/ modules/relays etc to be placed in substation.
7. FIELD INTERFACE
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7.1. Multi- core cables connected to junction boxes in the field, transmitting
conventional 4-20 mA signals from all type of field transmitters,
individually, will be connected to marshalling racks. In the marshalling
racks the signals will be connected to the I/O cards of the DCS
systems through pre-fab system cables. Separate RTD AI Cards need
to be provided for RTDs. Thermocouple AI card need to be considered
for thermocouple connection.
8. POWER SUPPLY
8.1. Power Supply Levels
8.1.1.
The different power supply levels used shall be as follows:
8.1.1.1.
Uninterruptible Power Supply (UPS,
by others): 230 V ± 2%; 50 Hz, ± 2%, 1Ф
8.1.1.2.
Standard (non-UPS) mains power supply : 240
V + 10%; 50 Hz, + 4 %, 1Ф
8.1.1.3.
DC Power Supply : 24V DC, ± 0.5 %
8.1.2.
The DC supply in 8.1.1.3 above shall be derived by
the vendor from the UPS by providing two or more
regulated SMPS in parallel redundant configuration.
8.1.3.
Any other power supply required by the vendor shall
be derived and distributed by him from the UPS / DC power
supply.
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8.2. Power Supply Distribution Philosophy
8.2.1.
The distribution of power to different plant loads at
various voltage levels shall be as per the following table:
Sr.
Type Of Load
Supply Type
No.
1.
DCS, printers, separately powered instruments,
230V AC, UPS
solenoid valves
2.
Panel lighting /socket outlets
240V AC, NonUPS
3.
2 Wire transmitters, interrogation of digital inputs,
24V DC
interposing relay / contactor coils, trip amplifiers,
active barriers, isolators, etc.
4.
Solenoid valves
24V DC, 230VAC,
110 VAC
8.2.2.
In the event of UPS failure the connected loads shall
be automatically transferred to the mains supply where the
voltage and frequency regulation shall be as per 8.1
above. (The voltage level shall be same as UPS) The DCS
hardware therefore, shall be designed for continuous
operation at these conditions. Vendor shall indicate the
maximum voltage and frequency variation that the different
components of the system can tolerate.
8.3. Bulk Power Supplies 24 V DC
8.3.1.
The number and quantity shall be sized by the vendor
as per requirement. These shall be in parallel redundant
configuration with diode ‘OR’ing unit. In case of a failure of
one unit, the redundant shall be capable of handling the
entire load without any voltage dip. Output of the diode unit
shall form a 24 V DC power supply bus, from which the
downstream distribution shall be done.
8.3.2.
Each bulk power supply shall be provided with
incoming and outgoing MCBs for ease of maintenance.
The MCBs on DC side shall be suitably derated for DC
duty.
8.3.3.
Individual power supply failure alarm shall be
available on the operator station. The priority of this alarm
shall be same as a system hardware alarm.
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8.3.4.
Output voltage adjustment facility is required. Output
shall be clamped to 28 V DC maximum. Regulation shall
be as per 8.1 above. Digital voltmeter to read output
voltage is required.
8.3.5.
Earth fault detection with alarm on operator station is
required.
9. ALARM MANAGEMENT
9.1.
The purpose of an alarm is to bring the operator's attention to an
abnormal event, such that he can take action to rectify the situation. During
normal operation the Alarm Philosophy shall be that there are no active
alarms present. To enable the operator to respond appropriately, alarms shall
be categorized according to the following three priorities reflecting the
severity of the abnormal situation, as a minimum.
9.1.1.
A "First Failure" indication shall discriminate between related
alarms to identify the first initiator of a trip with 1 mili second time
resolution in the operator console.
9.1.2.
A shutdown level alarm indicates that immediate operator
action is required to prevent a trip condition (in this case it is also
referred to as a pre-alarm), or is used for essential parameters for
proper operation of the plant (e.g. quality alarms) in DCS operator
console with diff. hooter/sound.
9.1.3.
Secondary alarms draw only attention to an abnormal
situation that could result in a severe operational upset if not acted
upon. This shall also be reported at DCS operator station with diff.
hooter /sound
9.1.4.
9.2.
Alarm acknowledgement and first failure resetting shall be from the DCS
keyboard, locally from equipment panels
9.3.
On measurements that can lead to a trip, pre-alarms shall be
implemented.
9.4. The alarm management of the DCS shall be developed with the following
objectives:
9.4.1.
Minimize the number of active alarms;
9.4.2.
Optimize the information contained in the alarms;
9.4.3.
Obtain effective alarm presentation by using Human Factor
design principles and practice.
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9.5.
Further techniques shall be employed to optimise the operator
interface to the alarm system.
9.6.
The DCS shall be compliant with Alarm Management standards
EEMUA 191 and ISA-18.02.
9.7.
Methods to be used are suppression techniques (static or dynamic),
first failure indication and alarm overview displays in addition to the alarm list.
The overview displays provide a layered structure of related alarms in
annunciation screens.
9.8.
Sequence of Events Recording system shall log all safety related
alarms, commands and status changes for post-trip analysis on a dedicated
PC station.
10.
CONTROL AND SAFEGUARDING DESIGN CRITERIA
10.1.
EXPANDABILITY
10.1.1. In I/O Count for, 20% spare capacity has been considered.
This minimum 20% spare capacity shall be provided in each of the
I/O cards in the form of spare channels. This spare capacity
should be completely pre-wired with all the intermediate
accessories like prefab cable, cable connector, barrier
/ isolator/relay up to marshalling
terminal.
10.1.2.
No I/O module in DCS shall be loaded more than 80%,
10.1.3. In addition, minimum 20% spare space in cabinets for
installation of spare I/O cards shall be available throughout the
system for allowing
undefined future expansion.
10.1.4. To allow for future expansion 20% spare capacity shall be
allowed &
terminated in multi core cables, junction boxes, etc,
marshalling
racks, patch panels and power supply units.
10.1.5. Communication networks and cables shall have a spare load
capacity of 50% as a minimum.
10.1.6. Plant wide networks shall have a node connection spare
allowance of 50 % as a minimum.
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SPECIFICATIONS FOR
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10.1.7. Local networks, if any, shall have a node connection spare
allowance
of 30 % as a minimum.
11.
DCS DESIGN CRITERIA
11.1. Minimum Hardware Requirements
11.1.1. The DCS and all the subsystems shall be able to
withstand the storage conditions at Senegal, West Africa
for long periods stretching to as much as 5~6 months
11.1.2. The system shall have a proven track record of
continuous successful operation in a chemical plant for a
minimum period of two years after successful SAT. Vendor
shall submit letters from end users to prove the above
criterion. No prototype hardware / software of any nature
shall be supplied
11.1.3. Offered system hardware shall be supported for at
least ten years from date of PO. Vendor shall give a
specific declaration to that effect.
11.1.4. The system shall be designed “fault tolerant” by
selecting components of proven quality and by proper
design. Redundancy shall be provided as a minimum as
per requirements given later in this document to improve
reliability and availability.
11.1.5. All electronic components / modules for controllers, I/O
subsystem including the termination assemblies, communication
interfaces, shall meet corrosion protection class G3 as per ANSI /
ISA S71.04. Type test certificates from an independent agency to
that effect shall be submitted. Vendor shall clearly identify
hardware which does not meet this requirement.
11.1.6. On-line replacement (hot swapping) of any module shall be
possible (i.e. removal and addition of a module without deenergizing the system). There shall be no interruption in the
system functioning while replacing a faulty module on-line.
11.1.7. For HART analog signals from field devices, all components
in the loop like barriers/isolators, trip amplifiers, Field Termination
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Assembly (FTA), input / module, etc., shall be HART pass through.
Patch cards with multiplexers are not preferred.
11.1.8. Barriers/isolators, FTAs, shall faithfully repeat analog signal
from 0 mA to 24.0 mA without clamping the same.
11.1.9. Analog input modules shall have the capability to read inputs
below 4mA and beyond 20mA as per NAMUR standard NE 43. It
shall be possible to set “bad PV” alarm for signals < 3.6 mA or >
21 mA and use the same in interlock logic.
11.1.10. Barriers, FTAs / input modules used for powering two wire
transmitters, shall have short circuit protection against accidental
earth fault. The same shall preferably through current limiting
without violating requirements in i above.
11.1.11. The system shall be protected from static electric / magnetic
fields as well as against commonly occurring EMI and RFI due to
walkie-talkie sets, mobile phones, pagers, nearby wi-fi networks,
operation of relays / contactors carrying heavy currents, etc. EMI /
RFI protection shall be as per latest IEEE / SAMA standards.
11.1.12. Volatile memory shall be protected with battery back-up.
Alarm annunciation shall be provided for low voltage of the battery.
11.1.13. A common physical layer diagnostic module shall be supplied
for a group of eight power conditioner modules. This shall sit on
the same motherboard. Necessary IIIrd party diagnostic software
required for the purpose is included in scope of supply. The faults
detected by the diagnostic module shall be annunciated on the
operator station. Vendor shall indicate the diagnostics available on
the physical layer.
11.2. Minimum Software Requirements:
11.2.1. Offered software shall be supported for at least ten
years from date of PO. The support includes removal of
bugs, installation of software patches for updates /
upgrades and making the same compatible with any
operating system changes. Vendor shall give specific
declaration to that effect. In any case whatever updates /
upgrades / improvements released for the software version
supplied, up to warranty period, are to be supplied and
installed without any price implication. Patches for removal
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software bugs shall be provided and installed free of cost
for ten years from date of PO.
11.2.2. The operator and engineering stations shall be “MS
WINDOWS”® based of latest approved version. Licensed
antivirus software shall be installed to guard the operating
system against external virus attacks. Regular updates on
antivirus software up to warranty period, are included in
scope of supply.
11.2.3. The DCS shall have the capability to exchange
information with other software platforms and shall be OPC
compliant. The necessary hardware and software
necessary to meet this requirement shall be considered by
the vendor.
11.2.4. System shall have extensive self-diagnostic software
routines capable of locating and identifying faults at least
up to module level and display of the same in detailed
diagnostic displays.
11.2.5. The system shall have in built ready-made software to detect
open sensors and bad process values with an alarm.
11.2.6. Self-tuning feature shall be available as a standard. It shall be
possible to download on-line, parameters computed by the
software either manually or automatically. The process shall not
get disturbed when a loop is being tuned.
11.2.7. Database shall be global. It shall reside preferably at one
point in the system and available to any node on the network. Data
addressing shall be by using tag name and not physical or logical
address.
11.2.8. Dynamic data shall be updated in all the operator stations
simultaneously. Any configuration changes made in the system
shall be downloaded to all the concerned stations simultaneously
and without any manual intervention, transparent to the user.
11.2.9. The system shall support a powerful and easy to use graphic
builder package. This shall include commonly used tools like cut
and paste, object embedding etc. Drawing tools commonly found
in CAD like midpoint of line, centre of circle, draw tangent, fill / unfill
an object, duplicate an object, zoom object, shall be supported.
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Package shall have extensive library of symbols for equipment,
piping components and instruments.
11.2.10. Control builder package shall support all the
languages recommended by IEC 61131 standard.
Configuration of loops shall be achieved using standard
pre-configured program blocks and linking the same.
Commonly available tools in “MS WINDOWS”® like drag
and drop, copy / paste, hyperlink, shall be available to
make the tasks simpler and faster. On line help shall be
available, just a mouse clicks away, in the form of tips,
explanations, examples, etc. Facility to enter users
comments (non-intelligent data) shall be available for ease
of understanding. The package shall support all the
necessary software for sequence and batch execution as
per ISA SP-88 recommendations
11.2.11. Alarm management features supported by the system shall
include alarm prioritising (at least 5 levels); alarm sorting / filtering
on priority, time span, plant unit, frequency of occurance, etc. It
shall be possible to deactivate nuisance / secondary alarms. It
shall be possible to organise alarm data in a browser view to
analyse the same as per user’s requirements. Dead band shall be
configurable individually for each alarm (not loopwise).
11.2.12. The system shall be capable of accepting signals
from the following existing Fieldbus standards:
11.2.12.1. Foundation Fieldbus (FF)
11.2.12.2. Profibus
11.2.12.3. DeviceNet
11.2.12.4. ASI-bus
11.2.13. The system bulk memory shall be sized assuming all analog
and digital inputs/outputs to be trended at a sampling rate of 1
second for a duration of 30 days. Data archival shall be supported.
It shall be possible to archive old data automatically after a certain
defined time period on to a storage media (CD, floppy, etc.) from
which it can be viewed on-line for analysis.
11.2.14. System shall have extensive self documentation tools. It shall
be possible to import in to the system / export from the system, tag
database, in a easy to use format like “MS EXCEL”® or “MS
ACCESS”® . E.g. it should be possible to extract from system /
import in to system; tag database, tag no, service description, IO
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SPECIFICATIONS FOR
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assignment, ranges, alarm value, trip values, controller action,
alarm priority, etc.; in Excel format. Similarly it shall be possible to
take print-outs of generated logic, loops and sequences in any of
the languages specified by IEC 61131. In case this is not a
standard feature of the system, necessary additional software shall
be offered to comply with these requirements.
11.2.15. Dynamic display of generated loops, logic,
sequences, shall be possible. It shall be possible to read
raw data, results of intermediate computations in a
dynamic form.
11.2.16. Offline simulation package shall be supported. This shall
include simulation and testing of control strategies, logics,
sequences; providing alerts and messages for configuration
errors; on any offline PC without the actual system hardware in
place. It shall be possible to enter data through keyboard to test
functioning of a loop for correctness in off-line mode before
downloading the same in to the system.
11.2.17. Configuration tool shall have both on-line and off-line
capabilities.
11.2.18. On line changes in configuration of loop / logic /sequence
shall be possible. Whenever a part of configuration is changed the
outputs (analog or digital) pertaining only to that part of existing
configuration shall be in ‘hold’ mode (held to last state). The rest
of the configuration and outputs shall remain unaffected. When the
downloading of configuration changes is complete, the controller
shall take over the execution of the loop / logic as per the new
configuration. This shall also apply to those cases when tag
numbers are added / deleted from a data base.
11.2.19. The system shall boot ifself automatically on restoration of
power after total power failure. This shall be a procedureless
operation without any intervention by the operator or engineer
whatsoever. During power failure, all the digital outputs / controller
outputs shall go to zero state, and all controllers shall fall back to
manual mode. On restoration of supply, the system shall be ready
to receive instructions from the operator without the requirement
of any system software files to be loaded , the controllers shall
remain in manual mode with outputs at zero, and digital outputs
shall assume their states as dictated by the logic / sequence.
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11.2.20. Forcing of digital outputs shall be possible even though this
may not be shown in the logic. This shall be password protected.
Whenever a output is bypassed, an alarm shall be generated. A
separate dedicated alarm summary shall highlight all the outputs
under bypassed state.
11.2.21. Time synchronisation shall be from Master GPS Clock which
shall act as a master clock. All connected sub-systems shall be
synchronised with the master for uniform time stamping of alarms
and events. Time synchronisation within system nodes and with
other systems shall be done at least once every hour. Alternatively,
11.3. Optional Software
11.3.1. Long Term Trend Archival Package: It shall run in
all Operator station. The package shall enable storing of
analog as well as digital data points (Selective) for 1 year
duration at 1 Min rate. Vendor shall clearly specify any
limitation on the number of tags v/s sampling rate. It should
be possible to change the sampling rate to lesser than 1
min up to 1 Sec if required.
11.4. DCS, by employing distributed intelligence and database
techniques,
shall provide highly secure, safe, reliable, maintainable,
effective
process / safety monitoring and control of the
production/ancillary
facilities, from a permanently manned Central
Control Room (CCR). DCS
shall not be a PLC/SCADA based system. PLC Hardware like CPU, I/O
modules etc. in any form are
not acceptable in DCS.
11.5. The system shall enable process monitoring, control, safety detection &
protection to be achieved, at several equipment nodes, with serial highspeed communications to the operator's console
employing VDU's,
keyboards, print server & printer, data storage devices, etc. 24” wide
screen LED type colour monitor.
11.6. The DCS shall employ Dual redundant (fault tolerant) communications
links. The system supplier shall prove that the system
hardware
redundancy, will achieve an availability figure
better than 99.99% per
control loop using his chosen hardware configuration.
11.7. Controllers should not be loaded more than 60%. If more number of
controllers
are required to meet 60% controller loading criteria, the same
should be included.
11.8. The system shall be fully configurable without specialized
programming
knowledge, using proven, fully de-bugged and tested Supplier's standard
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software packages. Sufficient online storage
shall be included to
accommodate the database and alarm, event
and historic data logs. To
achieve the reliability/availability targets required,
redundancy
requirements shall be calculated and
employed. Operational control of
the plant will normally be from the CCR. Facilities shall be provided such
that in the event of failure of operator workstations, the controllers shall
continue to provide control operation at the last known set point.
11.9. The system shall be built on the latest state-of- the-art hardware and
software platform and hardware/software/firmware revisions of
complete system will be latest at the time of supply. The system
architecture shall have Microsoft Windows (latest version) operating
systems and compatible hardware. Number of consoles envisaged is
indicated elsewhere in this document. There shall be a facility to
operate these loops from the adjacent Operator station in case of any
failure.
Client Server Architecture is not acceptable. All Workstations should be
directly sitting on Plant Communication Loop as INDEPENDENT
NODES.
No operating Station should be connected to Plant
communication loop through a server. All workstation should be
directly connected to main Plant communication loop as
independent
nodes with full functionality.
However, “remote monitoring stations" which are meant for remote
operation/ monitoring can be connected to plant communication l loop
through server in case distance is a limitation for Server-Server
configuration
11.10.
The system shall be 100% fault tolerant and dual redundant for
control processor, system bus, data highway, I/O for closed loops, power
supply and communication. This means, all central control
processors,
all communication processors and all other central rack
and
individual node’s common cards, all the communication cards,
networks and cables, etc. shall be 100% fault tolerant.. All the
hardware including control/communication processors, networks,
cables, all type of system cards, all type of I/O cards shall be hot
replaceable.
11.11.
All the I/O cards shall have individual channel to channel as well
channel to field isolation. Analog input/output cards shall be galvanically
isolated and digital input/output cards shall be optically isolated.
Group
isolated type or bulk I/O cards shall NOT be
accepted in the whole
system architecture. All I/O cards shall be
intelligent
type
with
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SPECIFICATIONS FOR
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microprocessor/microcontroller based hardware and capable of all type of
signal conditioning, self diagnostic, fail safe
value
configurable
(programmable) and time stamping at I/O card level.
11.12.
I/O cards’ Channel density shall not exceed the following limits
11.12.1. Analog Input
– 8 Channels
11.12.2. Analog Output
– 8 Channels
11.12.3. RTD card
- 8 Channels
11.12.4. TC card
- 8 channels
11.12.5. Digital Input
-32 Channels
11.12.6. Digital Output
-32 Channels
11.13.
All I/O cards in individual category shall be of same
type/model/revision only. No different bulk I/O cards or I/O cards with
degraded features shall be accepted in any of the category in a mix
mode supply.
11.14.
Input - output considerations
11.14.1. All cards will be provided with diagnostic features with High
diagnostic coverage per channel at component level, able to detect
any failure and giving a diagnostic alarm. Replacement of I/O cards
shall be possible while the DCS is powered.
11.14.2. Removal and insertion of a DCS I/O card shall not affect the
supply of field power to other loops connected to the DCS.
11.14.3. Shut down switches will work as follows: when the contact
coming from the switch is OPEN, the shutdown sequence will start.
This solution guarantees that plant shut down is initiated only if
requested by operator and not as a consequence of a single
hardware failure.
11.14.4. Bypass switch will deactivate a cause (or a group of causes,
according to interlock process requirements) only when the
contact coming from the switch is CLOSED. This way if there is a
hardware fault interlock deactivation will not occur.
11.14.5. The following type of I/O modules shall be provided for as a
minimum in the DCS but not limited to:
11.14.5.1. Digital input
11.14.5.1.1. All digital input must have interposing relays
in DCS Marshalling.
11.14.5.1.2. Wiring Between IO Card and Interposing
Relay Must be prefab. Cable.
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11.14.5.1.3. Interposing Relay board have redundant
power supply.
11.14.5.1.4. Coil side power and contact side power must
be from different redundant power supply system.
11.14.5.1.5. Coil side power must Non-UPS supply. While
contact side is UPS supply .
11.14.5.1.6. Interposing Relay Rating: 24V dc to 230 V
DC/AC coil supply. Contact Rating: As per DCS IO
card.
11.14.5.2. Analogue Inputs/outputs
11.14.5.2.1. 4-20 mA dc , 1-5 V dc two wire type
11.14.5.2.2. All I/O circuits must be provided with galvanic
isolation using isolating barriers.
11.14.5.2.3. Field Terminal Assembly (FTA) or
Marshalling Terminal Assembly Must have
redundant Power supply.
11.14.5.3. Digital Outputs
11.14.5.3.1. All digital outputs shall be equipped with
protection against voltage surges caused by
inductive loads.
11.14.5.3.2. Digital outputs shall be static type, free
voltage contacts. The outputs shall be galvanic ally
or optically isolated.
11.14.5.3.3. Outputs shall be without any common wiring
and no looping in the terminal end is allowed.
11.14.5.3.4. The interposing relays shall be provided in
the DCS Marshalling to match the required Contact
ratings.
11.14.5.3.4.1. for Solenoid valves and MOV’s 24 V
TO 230 V DC/AC - 3 Amps.
11.14.5.3.4.2. for MCC 24 V TO 230 V DC/AC - 5
Amps.
11.14.5.3.5. Interposing Relay Coil voltage: 24 V DC
11.14.5.3.6. Interposing relay board must have redundant
power supply.
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11.15.
All digital input terminal blocks and all digital output
terminal
blocks
shall be fused Push Through
type. (Phoneix Contact make)
11.16.
The scan time of all type of analog/digital inputs
cards & DCS algorithm (Scan time means the sum of total
time required for
reading an input, running control
algorithm and writing the output
values) shall be better
than 250 milli-seconds for any type of
channel.
11.17.
There shall be minimum 1 nos. of engineering station
software/personalities in overall DCS architecture, from where the
complete DCS project can be developed and deployed on any other
operator/control station, independently. Non-availability of both of these
engineering stations simultaneously shall not affect the plant normal
operation and shall neither cause any historical/trend data
loss.
All
operator station shall be independent of engineering
stations,
self
bootable and do not require engineering station for
putting them into
normal operation or restoring them after rebooting,
once the developed
project is deployed. System should allow on-line modification, addition /
deletion or change in any control loop or part
thereof.
11.18.
All operator stations and engineering stations shall be OPC
compliant without any upper limit on number of tags. However, if
there
is any specific limit applicable on the proposed system, it is to be specified.
Two Operating station must have OPC Server facility with
Required
licence. There must not OPC tag upper limit.
11.19.
Complete system hardware/software and communication load shall
not exceed 50% system load even after the complete implementation of
project and running at peak load. This includes redundant
control
processor load also.
11.20.
System shall have 50% spare margin in software memory/load for
future spare addition without replacing/upgrading any existing
system hardware/software at all the levels. System shall be capable
of loading up to 100% without any overrun/degradation of
performance, etc. System shall report all type of load limit alarms,
diagnostic alarms upto channel level, communication alarms,
system hardware failure alarm and other global information with
alarm
facility on engineering/operator station in real time with 1
second
resolution
11.21.
System shall have 50% spare margin in software
memory/load for
future
spare
addition
without
replacing/upgrading any existing system
hardware/software at all the levels. System shall be capable
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SPECIFICATIONS FOR
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of loading up to 100% without any overrun/degradation of
performance, etc. System shall report all type of load limit
alarms, diagnostic
alarms
upto
channel
level,
communication alarms,
system hardware failure alarm
and other global information with alarm
facility
on
engineering/operator station in real time with 1 second
resolution.
11.22.
The
system
shall
support
all
various
type
of
control/interlock/sequence algorithm and shall also support various high
level programming language like VB, C/C++ in real time control
application, in addition to standard control algorithms available in the
DCS.
11.23.
System
shall
support
various
Hourly/Shift/Daily/Monthly
Reports/Logs, Totalizers reports, SNAP shot reports, etc. in Microsoft
excel format only. The layout and type of reports/data, nos.
of tags per
report, etc. shall be as per owner’s requirement. All the operator
station,
engineering stations shall be equipped with MS Office
licensed
copy.
System shall support history for min. 5000
tags, out of which 2000
points shall be configurable for 1 second resolution, 1000 points shall be
configurable for 2 seconds interval and remaining shall be configurable from
5 to 10 seconds. There
shall be no limit on history data retention time,
except the hard disk size. All the stations, wherever engineering database
of complete project and historical/run time data is stored, shall be
equipped with redundant hard disk with RAID1 configuration, to prevent any
data
loss. This will include not only the engineering station but all the
operator station also, wherever applicable
11.24.
System shall support 1 second time resolution real time trend for all
the system tag/parameters, without any time limit. The minimum x –
axis time span for real time trend with 1 second sample rate shall be
30 minutes. Also, all PID loop face plate display shall have real
time/historical trend window by default for min. three parameters, i.e.
measured or process variable, operator entered or
remote/calculated
set-point and output value or manipulated value for that particular loop.
11.25.
DCS system shall have latest; windows based
alarm manager with 1 second or better time resolution. In
addition to various process alarms, the system shall also
store operator action journal, system
error messages,
any other event, etc. Alarm manager shall also have
historian facilities and there shall not be any storage limit
except hard disk size for retention period of various
alarms/events.
11.26.
Complete system hardware shall be certified for ISA
G3 class
corrosion level protection and shall be
compatible with various
RFI/EMI immunity as per IEC.
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The complete system shall be
supplied with 800 mm
(W) x 800 mm (D) x 2100 mm (H) standard
RITTAL
make panels with RAL7032 colour shade. Marshalling
philosophy and
panel segregation for various type of
I/O shall
be as per Owner’s requirement, which is
already described above.
11.27.
DCS system shall have fast MODBUS I/O
cards/Communication
gateways for interconnecting
with other various types of control systems
like
Speed/Vibration monitoring system, etc. via RS485
interface and MODBUS protocol AND via ethernet
MODBUS TCP.
The communication module and links
shall be 100% fault tolerant. The signal exchange between
various other system and DCS shall
be hardwired if
they are to be used for control/decision making purpose
in DCS. All serial links shall be connected to dedicated
gateways/cards. These gateways shall be independent
and not combined with process controllers. Serial cards
shall be redundant.
11.28.
Vendor shall provide 230 V AC +/- 10% at 50 Hz 3/+1 Hz, UPS grade, floating power supply for complete
DCS system at one location in cabinet room up to PDB
panels. All digital input shall have 24 V DC interrogation
voltage level. All Analog cards shall be
capable
of
accepting 2 wire and 4 wire analog inputs and shall supply
24 V DC to field transmitters. All Digital output cards shall
drive 24 V
DC, 4 NO/NC, socket mounted, interposing
relays with
24V to
230 VAC/DC/5 Amp contact
ratings. All field loads
from Digital Output
cards,
including Solenoid valves, MCC switch
gear
signals,
etc. shall be interfaced via these interposing relays
only. The
output cards driving the MCC related output
relays ( which are to
be wired to MCC/Sub station)
shall be accommodated
in
Digital Interface panel
as specified above, separately to avoid any
Interference problems in low voltage instrument signal
cables. There shall be intrinsically safe active barriers of
MTL / P&F
make for
analog inputs & outputs, and
all NAMUR sensors (proximity
switches) for Sulphur
Zone and Boiler Zone. Isolators need to be
considerd
for AI signals between DCS and MCC/Electrical systems.
11.29.
For various categories of I/O cards, 20% (minimum one set where
20% works out to be less than one) of each type of spare I/O
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SPECIFICATIONS FOR
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modules as ware house spares shall be considered. These spare
modules shall also include related termination assembly, isolating
barriers and all system pre-fab cables. For modules, (controllers,
communication modules, power supplies etc.) which are specified as
redundant, 20% ware house spares shall be considered or 1 pair of
each type if 20% works out to be less than one.
11.30.
The offered system shall be supported by the DCS
vendor for min.
15 years for all type of hardware and
software spares and service
supports
11.31.
While preparing DCS database, all configuration like graphic
symbols, colour codes, control/logic schematics, etc. shall be based
on ISA standards.
11.32.
The following Tagging and Identification
philosophy for Equipment,
wiring and terminals
shall be followed
11.32.1. Each Cabinet, Workstation, operator station,
card file, equipment, shall have identification
label/Nameplate on the front and rear. The
identification label shall be of laminated plastic or
approved equal with white dull surface finish and
information engraved in Black. These labels shall
be permanently affixed with fasteners or Bonding
to the Cabinets / equipment. Vendor to provide the
Nameplate and labelling schedules for approval
by ICS.
11.32.2. All the instruments, pushbuttons, switches,
lamps etc. mounted in the Cabinets/ Consoles
shall be identified by two identical nameplates,
one on the front and one on inside the cabinet/
Console. The nameplates shall be made of plastic
or stainless steel inscribed with tag no. and
service. The nameplates shall be attached with
non-corrosive fasteners.
11.32.3. All wires connected to Terminal blocks,
including I/O module termination panels shall be
tagged with 2 identification tags. The first Tag
shall (closest to the end of the wire) identify the
terminal number to which the wire is physically
connected. The second tag shall identify the
terminal or device number to which the opposite
end of the wire is connected. Wires markers shall
be slip-on, heat shrink, permanently embossed,
sleeve type.
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11.32.4. Each terminal block shall be labelled with a
sequential terminal identification number. Each
row or column of terminal blocks shall be labelled
with a unique Identification name or number.
11.32.5. Multicore cables with connector plugs shall
be labelled with 2 identification tags. The first tag
(closest to the plug) shall identify the cabinet
identifier, device and socket to which the plug is
to be connected. The second tag shall identify the
cabinet identifier, socket or device to which the
opposite end of the cable is connected.
11.33.
SYSTEM TERMINATIONS
11.33.1. The termination in DCS panels have to be
segregated per voltage level and voltage
category.
11.33.1.1. Analog (Intrinsically safe)
11.33.1.2. Analog (Non- intrinsically safe)
11.33.1.3. Discrete (Explosion proof)
11.33.1.4. Power supply cables.
11.33.1.5. Control signal cables between MCC
and control room.
11.33.2. Terminals shall be phoenix contact (push
through type) type and shall be adequate for
wiring of flexible wires of 0.5 - 2.5 mm2 section.
No double terminal blocks may be used.
11.33.3. Terminal panels with electronic devices
and/or relays mounted shall have a dedicated
mechanical protection.
11.33.4. Each terminal panel shall have the individual
identification tag and each channel shall be
identified by the instrument connected with tag
name.
11.33.5. The terminal panel connection to the I/O
cards shall be through prefabricated cable with
plug-in connector.
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11.33.6. The Terminals provided in the Marshalling
cabinets shall be single tier and of suitable size
depending upon the current rating and the size of
the cable being terminated.
11.33.7. The terminals shall be of phoenix contact
push through for the signal from / to field.
Individual fuses and indicating LED/Lamps for
indicating signal status shall be provided for each
Digital O/P channel.
11.33.8. The digital outputs shall have LED/Lamps for
indicating Fuse blown status.
11.34.
Unauthorized access to the system shall be
protected by means of
suitable Hardware Key locks
and Software passwords. Different levels of access shall be
provided for the Operators and Engineers
by means
of passwords and key locks.
11.35.
COMMUNICATION SUB SYSTEM
11.35.1. The Communication sub system cable shall
be secured in conduit inside the control room. In
such
installations
where
communication
subsystem extends outdoor and subjected to
intermittent exposure to water or condensed
moisture, it must be enclosed in rigid conduit. The
communication subsystem, in such case must
perform to the offered specifications for error rate,
signal attenuation, noise immunity etc.
11.35.2. DCS Bus shall be fully deterministic based
on IEEE802.4.
11.35.3. Communication speed on the system bus
shall be minimum 100Mpbs and overall system
performance shall not be degraded whether
communication subsystem is 10% loaded or
100% loaded.
11.35.4. Vendor must furnish BUS LOADING
calculations for each system. I.e. controller & Data
Acquisition subsystem, console subsystem and
communication subsystem. The Loading figures
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shall be demonstrated by vendor at FAT and
finally during SAT. Vendor quoted Hardware and
software shall meet these loading requirements.
In case actual loading is found to be higher than
the specified figure, vendor shall supply additional
hardware / software to meet the requirements of
this requisition without any commercial
implications.
11.35.5. System bus, subsystem bus and I/O Bus
redundancy shall be true redundant with 2 sets of
Bus and redundant Cards.
11.35.6. DCS communication sub system shall be
OPC compliant.
11.36.
SELF TUNNING
11.36.1. It shall be possible to tune control loops
automatically on selective basis. The operator
shall either load tuning parameters computed by
the system automatically or manually.
11.36.2. The software for the loop tuning may reside /
run on any system hardware including controller
and Data acquisition subsystem, Operator
console subsystem, supervisory computer etc.
The tuning package shall ensure that the system
not disturbed whenever a loop is being tuned.
Tuning package shall not slow or load the system
performance.
11.37.
POWER SUPPLY
11.37.1. Vendor to ensure the DCS component shall
not get affected or failed due to blackouts. Fail
Safe Operation of the system to be ensured under
the following conditions.
11.37.1.1. Total Power failure
11.37.1.2. Voltage Variation more than ± 10%
11.37.1.3. Frequency variation More than ± 3%
11.37.1.4. Air conditioning failure resulting in
temperature exceeding 40 deg C.
11.37.2. 230V AC, 50HZ UPS redundant feeder shall
be made available to the vendor at one point in
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UPS room which is around 100 meters from
control room.. Any other voltage requirement shall
be derived from the above source by the vendor.
11.37.3. Bulk power supply provided by vendor for
transmitter power or for any other application shall
have the following specifications:
11.37.4. Bulk power supplies shall be redundant
floating with +, - 0.5V tolerance.
11.37.5. Separate power supplies shall be provided
for controller /subsystem.
11.37.6. Status indication for each power supply at
operator console
11.37.7. Switch / Fuse/MCB for each loop.
11.37.8. Each power supply shall be sized for 150%
of load.
11.37.9. The system shall restart without manual
intervention after resuming the power sully with in
CPU battery life.
11.37.10. Separate Diode O ring/ Isolator unit shall be
provided for each bulk power supply.
11.38.
EARTHING REQUIREMENT
11.38.1. Vendor to specify the earthling requirements
and provide the required drawing as per their
standards.
11.38.2. Vendor to provide the connectivity of existing
or new earth pit and any additional requirement of
earth pit and other details
11.39.
CABINETS, RACKS AND PANELS
11.39.1. All cabinets, panels and racks shall be
designed without congestion for ease of
maintenance. Racks / cabinets shall be designed
to take care of the following:
11.39.2. No marshalling rack / cabinet have more
than 600 terminals in any case.
11.39.3. All the spare cores shall be terminated on the
marshalling rack. No cable / core shall be left
unterminated in the rack / cabinet.
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11.39.4. All spare cores shall be terminated in TB’s
at top of the each marshalling cabinets with proper
ferrule details.
11.39.5. No terminal or terminal strip, MCB shall be
located on the side panel of the rack / cabinet.
11.39.6. Quality of all the panels and consoles shall
be of highest quality as per good engineering
practice and to the satisfaction of ICS engineer in
charge.
11.39.7. Manufacturer of the panel shall be Rittal or
equivalent, this shall be finalized during detailed
engineering.
11.40.
SPARES PHILOSOPHY
11.40.1. Installed engineering spares of 10% shall be
provided in each subsystem for each type of
module to enhance the system functional
requirements including DCS and hardwired
instruments.
11.40.2. In addition, the system shall have the
following minimum spare capacity.
11.40.2.1. The controller and Data acquisition
racks, Analog and digital marshalling racks
shall have 20% usable spare space for
installing additional I/O modules for future
use.
11.40.2.2. Each operator console shall contain
20% usable spare group and related
display capability.
11.40.2.3. The system shall have capability to
extend its historical trending, logging and
user’s memory by 20% to meet future
expansion with / without adding additional
memory modules.
11.40.2.4. I/O racks of DCS shall have 20%
usable spare space for installing additional
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I/O cards of each type in future. However,
internal wiring for the same shall be
connected up to the I/O terminals.
11.40.2.5. Processor system of DCS shall have
capability to execute additional 20% logic.
Further it shall be possible to extend the
memory by 20% at a later stage.
11.40.2.6. Usable spare space in cabinets and
marshalling racks to install 20% spare
hardwire items like barriers, trip amplifiers,
and relays etc. including terminals in future.
11.40.3. Mandatory spares shall be 10% of each type
of module with minimum of one module for each
type or whichever is higher shall be supplied.
11.40.4. System spare capacity shall be provided as
follows:
11.40.4.1. Bus capacity :
40%
11.40.4.2. No. of nodes :
50%
11.40.4.3. Vendor shall provide Min. 50%
expandability on node connectivity on
redundant communication subsystem for
each kind of devices connected to the
network.
11.41.
System loading
11.41.1. DCS shall be sized in such a way to
guarantee further expansion to End-User.
11.41.2. Details about software loading of DCS are
referred in the different sections of this
specification. They will apply to:
11.41.2.1. Communication loading : 60 %
11.41.2.2. Mass memory loading : 60 %
11.41.2.3. Process computations : 60 %
11.41.2.4. Operator console :
60 %
11.41.3. The above software loading figures shall
apply to the fully configured system,
comprehensive of spare.
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11.42.
Vendor to confirm offered controller card and IO card shall be
protected as per ISA GX CLASS 71.04 corrosive environment protection or
better and relevant certificate shall be enclosed along with the offer
In case of any conflict between above general requirement/guide lines,
the more stringent DCS specifications will be followed.
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12.
SPECIFICATIONS FOR
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SYSTEM OVERVIEW
12.1. The DCS shall have the following main components:
12.1.1. Operator / engineering stations consisting of PCs, Video
Display Units (VDU), keyboards / mouse, auxiliary consoles, etc.
12.1.2. Peripheral devices like printers.
12.1.3. Multi-loop controllers and data acquisition system.
12.1.4. Communication networks and associated hardware.
12.1.5. Gateways for communication with other devices.
12.1.6. Marshalling cabinets.
12.1.7. System hardware cabinets.
12.1.8. Power distribution cabinets.
12.1.9. Control room furniture
12.1.10. Interconnecting cables.
12.1.11. Any other device needed to implement the requirements of
this specification but not covered above.
12.1.12. Any other specific device needed to implement requirements
of this specification.
12.1.13. Brief functional requirements of each of the above are given
in the specification.
12.1.14. The system shall be dual redundant and 100% fault tolerant.
This means, all central control processors, all communication
processors and all other central rack and individual node’s
INTERFACE cards, all the communication cards, networks and
cables, etc. shall be 100% fault tolerant and dual redundant. All
the system hardware of DCS shall have ISA G3 level corrosion
protection. All the hardware including control/communication
processors, networks, cables, all type of system cards, all type of
I/O cards shall be hot replaceable.
12.1.15. The system shall be built on the latest state-of- the-art
hardware and software platform and hardware/software/firmware
revisions of complete system will be latest at the time of supply.
The system architecture shall have latest version of operating
systems and compatible hardware. All the operator station and
engineering station shall equipped with 24” wide screen LED type
colour monitor. DCS: FIVE No’s operator stations. (4 in CCR and
1 in shift incharge room), two No’s Engineering stations, two No’s
remote operator stations for monitoring, are envisaged. These
stations shall be placed in DAROU-1 situated approximately 500
meters from the CCR.
12.1.16. There shall be a facility to operate these loops from the
adjacent Operator station in case of any failure. In addition to total
nos. of operator stations, there shall be 1 operator station for shift
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engineers inside control room. This will be same as other operator
station, except it will not be accommodated in operator console but
will be provided with table top furniture.
12.1.17. Client Server Architecture is not acceptable. All Workstations
should be directly sitting on Plant Communication Loop as
INDEPENDENT NODES.
No operating Station should be
connected to Plant communication loop through a server. All
workstation should be directly connected to main Plant
communication loop as independent nodes. However, “remote
monitoring stations" can be connected to plant communication
loop through server.
12.1.18. Complete system hardware/software and communication
load shall not exceed 50% system load even after the complete
implementation of project and running at peak load. This includes
redundant control processor load also.
12.2. Operator station consisting of:
12.2.1. 24” wide screen LED type colour monitor video display units
(VDUS) with related system hardware like full fledge server grade
machine with 32 GB RAM and 1TB RAID-I SSD, DVD writer, as a
minimum. The hardware configuration of all operator station shall
be same as that of engineering stations and license copy of
operating system.
12.2.2. Operator’s/engineer’s
touchscreen.
keyboards
with
mouse
12.2.3. Dummy consoles to mount push buttons,
hardwired/assignable instruments, annunciators etc.
12.2.4.
Printers with furniture.
12.2.5.
Hard copy units with furniture.
and
lamps,
12.3. Multi-loop controllers & Data acquisition system
12.3.1. It shall be fully redundant and fault tolerant with hotswappable redundant modules. The scan time of all type of
analog/digital inputs cards & DCS algorithm (Scan time means the
sum of total time required for reading an input, running control
algorithm and writing the output values) shall be better than the
required scan time of the fastest running control/closed loop like
anti surge algorithm in the plant for various turbo machinery etc.
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However, in any case, this shall not be more than 250 milliseconds for any type of channel. The system shall support all
various type of control/interlock/sequence algorithm and shall also
support various high level programming language like VB, C/C++
in real time control application, in addition to standard control
algorithms available in the DCS
12.4. I/O processing units:
12.4.1. All the I/O cards shall have individual channel to channel as
well channel to field isolation. Analog input/output cards shall be
galvanically isolated and digital input/output cards shall be optically
isolated. Group isolated type or bulk I/O cards shall NOT be
accepted in the whole system architecture. All I/O cards shall be
intelligent type with microprocessor/microcontroller based
hardware and capable of all type of signal conditioning, self
diagnostic, fail safe value configurable (programmable) and time
stamping at I/O card level.
12.4.2. All I/O cards in individual category shall be of same
type/model/revision only. No diff bulk I/O cards or I/O cards with
degraded features shall be accepted in any of the category in a
mix mode supply
12.5.
Data storage devices like SSD, portable USB hard disks, DVDs etc.
12.6. Communication network and associated hardware.
12.7. There shall be minimum 1 nos. of engineering station
software/personalities in overall DCS architecture, from where the complete
DCS project can be developed and deployed on any other operator/control
station, independently. These engineering stations shall be used as operator
station also. However non-availability of both of these engineering stations
simultaneously shall not affect the plant normal operation and shall neither
cause any historical/trend data loss. All operator station shall be independent
of engineering stations, self bootable and do not require engineering station
for putting them into normal operation or restoring them after rebooting, once
the developed project is deployed. System should allow on-line modification,
addition / deletion or change in any control loop or part thereof.
12.8. Gateways for communication with other devices. This includes Bently
Nevada 3500 series vibration monitoring systems, WOODWARD make
Digital Governors, Anti-surge system for turbo machinery etc
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13.
SPECIFICATIONS FOR
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FUNCTIONAL SPECIFICATIONS
13.1. FUNCTIONAL REQUIREMENTS
13.1.1. The system, as a minimum, shall meet the following
requirements without the supervisory computer:
13.1.1.1. Control
13.1.1.2. Data acquisition and monitoring
13.1.1.3. Alarming
13.1.1.4. Logging and report generation
13.1.1.5. Historical data storage
13.1.1.6. Trending
13.1.2. System shall have some free memory space available for the
user and CPU shall have the additional capability to perform
advance control functions, process optimization programs or
generate management reports as specified in job specification in
addition to space requirements. The availability of process control
language shall be preferred.
13.1.3. Whenever information network is specified, the system shall
meet any or all the following requirements:13.1.3.1. Centralized information system
13.1.3.2. Statistical process control/statistical quality control
13.1.4. Computer integrated manufacturing with information transfer
to achieve functions like production and preventive maintenance
scheduling and plant wide coordination etc.
13.1.5. Self-documentation
13.2. Operator Station (OS)
13.2.1. Each OS shall be a PC based workstation. It shall be used by
the operators to control and monitor the plant.
13.2.2. Each OS shall have access to complete or part database of
the plant as per requirements. Refer detailed system architecture
diagram attached for details.
13.2.3. Software masking facility shall be available with which it shall
be possible to inhibit selectively, operation of certain plant units,
from an OS or a group of OS. From any OS within a group,
dedicated to a plant unit / unit, it shall be possible to operate /
control all the tags assigned to the unit / units; whereas tags from
units not assigned to the OS can only be viewed.
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13.2.4. Each OS shall be PC based, standalone type, with its own
power supply, display screen, CPU and memory, communication
interface, keyboard, and mouse.
13.2.5. Each OS shall have the following specifications:
13.2.5.1. PC type : INDUSTRIAL GRADE vendor’s approved
make
13.2.5.2. CPU : Pentium core duo i7 4GHz,(min) or equivalent.
13.2.5.3. Display
: Colour, 24” , LED
13.2.5.4. Display arrangement
: Double tier
13.2.5.5. Port to drive large screen display : Required
13.2.5.6. SSD : 1TB min RAID-5.
13.2.5.7. RAM : 32 GB
13.2.5.8. GRAPHIC CARD: 4 GB
13.2.5.9. CD/DVD, read / write drive : required
13.2.5.10. USB ports : USB 3.0 ( 8 nos)
13.2.5.11. Type C ports: 3 Nos
13.2.5.12. HDMI PORTS: 2 NOS
13.2.5.13. DP PORT : 2 NOS
13.2.5.14. Interface with data highway
: Redundant
13.2.5.15. Mouse
: Optical
13.2.5.16. Keyboard
: Membrane type dust / spill proof,
Additionally QUERTY key board shall also be supplied.
13.2.5.17. Dedicated assignable keys on keyboard : Required
13.2.5.18. A group of OS shall be arranged to form an operator
console
13.2.5.19. The consoles shall be suitably provided with cooling
fans & filters. The CPUs shall be placed on the sliding type
pull out plates for ease of maintenance.
13.2.5.20. FAN FAILURE ALARM MUST CONSIDER
13.2.5.21. Each operator station shall be accommodated
in its own independent console/furniture with the
best befitting furniture with good system ergonomics
and aesthetic. All the consoles of operator stations
shall have cooling fans and filter louvers
13.2.5.22. Failure of any one workstation should not affect
more than one operator station VDU
13.3. Engineering Station (ES)
13.3.1. This shall contain the necessary software required for
engineering and configuration. It shall be used to perform the
following functions:
13.3.1.1. To add / delete a system node through the system
builder package.
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13.3.1.2. To configure a node and assign hardware to it.
13.3.1.3. To build graphics and other displays using the display
builder package.
13.3.1.4. To configure control / monitoring loops, build logic /
sequences.
13.3.1.5. To write / edit user written programs in higher level
languages supported by the system.
13.3.1.6. To download the generated application software to
different system nodes.
13.3.1.7. To generate self-documentation.
13.3.2.
Each ES shall have the following specifications
13.3.2.1. PC type
: Commercial grade vendor’s approved
make
13.3.2.2. CPU : Intel® Xeon® processor (E5-1620 v3, QuadCore,3.5 GHz ). Or equivalent
13.3.2.3. Display
: Colour, 24”, LED
13.3.2.4. SSD: 1 TB with RAID 5
13.3.2.5. CD / DVD read / write drive
: required
13.3.2.6. Graphics Card
: NVIDIA 4GB Graphics Card
13.3.2.7. USB ports : 8
13.3.2.8. Interface with data highway: Redundant
13.3.2.9. Mouse
: USB Optical Scroll mouse
13.3.2.10. Keyboard
: QUERTY, USB Type
13.3.2.11. EXPANSION SLOTS:
2 X PCI e Gen3 x16 slot
1 X PCI e Gen3 x16 slot /x8 connector
1 x PCI e Gen2 x4 slot/x4 connector
1 X PCI e Gen2 x1 slot
1 x PCI slot
13.3.2.12. COMMUNICATION PORTS:
USB 3.0 - 1 (Front),
3 (Rear) USB 2.0 - 3 (Front), 3 (Rear)
13.3.2.13. Type C ports: 3 Nos
13.3.2.14. HDMI PORTS: 2 NOS
13.3.2.15. DP PORT : 2 NOS
13.3.3. One number of CD / DVD (combination) read / write drive
shall be supplied loose. The combo drive shall be latest state of art
with software for labelling of a CD/DVD. It shall be supplied with its
power adapter, USB cable and the necessary R/W licensed
software. This can be plugged in ES to load the licensed software
or its updates in the system. The necessary drivers required for
this shall be loaded in the ES.
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13.3.4. Whereas one engineering station should be sufficient to
configure entire system, multiple engineering stations on a single
highway should be supported. This will help in system engineering
for different plant units simultaneously / from different locations.
13.3.5. If the vendors architecture is based on client /server concept
where the server is the repository of the complete database and
operator stations / controllers are the clients, the servers shall be
fully redundant. Each server shall have RAID 1 architecture as a
minimum. The necessary software for operation and engineering
shall follow concurrent users’ philosophy. Vendor to confirm where
will the optional software listed u/s 6.4 reside.
13.3.6. ES can be used as OS if required but not vice-versa.
13.4. Standard Displays
The DCS shall have the following standard displays as a minimum:
13.4.1.
Overview Display
13.4.1.1. This shall give an idea of the overall plant status with
less emphasis on details. This can either be in the form of
a deviation overview, overview of various plant units, alarm
status of all tags etc. This display shall not be used for plant
control. Similarly, no alarm shall be acknowledged from this
display. It should be possible to approach any other
operating display from overview with minimum of
operations. All these features shall be user configurable.
13.4.2. Group Display
13.4.2.1. This shall enable an operator to view a group of tags
(analog or digital in any combination) in the form of
faceplates similar to instruments on a conventional control
panel. Operator can do all the usual control actions and
operate the plant through this display. Alarm status of a loop
shall be available in this display.
13.4.2.2. Loop parameters like alarm status, PV, SV, MV values,
mode status (Auto/Manual/Cascade) etc. shall be displayed
prominently for each loop.
This display should be
conveniently linked to the plant overview display, detailed
loop status display and also to the relevant graphic pages
of the plant, for ease of operation.
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13.4.3.
SPECIFICATIONS FOR
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Detailed Loop Status Display
13.4.3.1. This shall be used by engineers to analyse the
behaviour of a loop. All loop constants can be changed only
through this display. Tuning of a loop shall be done using
this display. For this purpose, real-time trends of PV, SV,
MV shall be available for the latest 30 minutes. Password
protection shall be provided for access to tuning
parameters.
13.4.3.2. This shall give in analog / digital form all the
parameters of a particular loop like alarm set points, P, I, D
values bias, loop status, PV, SV, MV values, limits on output
or set point, algorithm description, controller action, other
configuration details etc. This display shall be used mainly
by engineers for changing constants, tuning a loop etc.
Real time trends of PV, MV, SV for tuning purposes shall be
available in this display. The sampling frequency for trends
in this display shall be minimum 1s with configurable dead
band for each parameter and the display time minimum 1030 minutes.
13.4.4.
Displays for Alarm Handling
13.4.4.1. These shall chronologically list all the alarms in a plant.
Operators can acknowledge and reset alarms through this
display. Acknowledging an alarm shall be possible either
through a dedicated key on the keyboard or through mouse
click. Information such as tag number, alarm description,
time of occurrence / return to normal, value, priority, shall
be available as a minimum.
13.4.4.2. Five levels of priority shall be available. Each will have
different audible and visible means of annunciation. System
alarms shall be clearly distinguished from other alarms. It
shall be possible to assign alarms on absolute values/rate
of change of a variable. Variable can be anything from a PV,
SV, MV, deviation, ratio, or any intermediate computed
values in an algorithm. Latest process alarm shall be always
available in any display.
13.4.4.3. This shall be one of the most important displays of the
system.
This shall have following features as a
minimum.
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13.4.4.3.1. DCS system shall have latest; Alarm manager with 1 second
or better time resolution. In addition to various process alarms, the
system shall also store operator action journal, system error
messages, any other event, etc. Alarm manager shall also have
historian facilities and there shall not be any storage limit except
hard disk size for retention period of various alarms/events.
13.4.4.3.2. A list of alarms based on occurrence with most recent alarm
on top.
13.4.4.3.3. A common list of latest 100 alarms for the whole plant in
chronological order.
13.4.4.3.4. Ack/scrolling ALM history and most recent alarms shall be
possible through software targets on the same display.
13.4.4.3.5. The alarm list in each case shall give the tag no., the service
description, type of alarm and the time of occurrence, status,
acknowledgement information. BIDDER to specify total number of
alarms per page.
13.4.4.3.6. It shall be possible to assign alarms on PV, SV, MV, rate of
change (PV, SV), deviation, ratio, as well as on any intermediate
computed value in case of a complicated algorithm.
13.4.4.3.7. The system should have minimum 5 levels of alarm priority
with different colour and tone.
13.4.4.4.
Emergency Alarms
13.4.4.4.1.
These shall be grouped for the plant separately from
other alarms. Acknowledgment of these shall be through a
separate key with LED, dedicated for the purpose and a separate
hooter shall be provided for the same. These shall be logged
automatically on the printer. The security level should be such that
these cannot be disabled by operator or supervisor but only by
engineer through a key switch and password.
13.4.4.5.
High Priority Alarms
13.4.4.5.1. These shall be similar to emergency alarms except that all
high priority alarms shall be acknowledged through a separate key
with LED assigned for the purpose. Those shall be logged
automatically on the printer and can be disabled only by
supervisor/engineer through a key switch and password.
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13.4.4.6.
SPECIFICATIONS FOR
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Low Priority Alarms
13.4.4.6.1. These should be acknowledged through a separate
dedicated key with LED. It should be possible for operator to
disable the alarms. However, logging of the same should not be
disabled.
13.4.4.7. It should be possible to disable alarms one by one (i.e.
tag-wise) or globally in a unit of the plant through a single
command.
13.4.4.8. It should be possible to assign different priorities to
more than one alarm for the same tag. (e.g. it should be
possible to assign different priorities to “high” & “low” alarms
of the same loop).
13.4.4.9.
The system software should automatically
histories all alarms earlier than the latest 100 alarms..
13.4.4.10. All system alarms (hardware & software) shall be
available in a separate alarm summary with its own
acknowledgment key and a dedicated hooter.
13.4.4.11. In alarm system, a common list of all defeated alarms
shall appear disregarding their alarm types, priorities,
grouping, unit etc.
13.4.5.
Trend Displays
These shall display one or more variables in a graphical form
as in a chart recorder. It shall have the following minimum features.
13.4.5.1. Select / delete a tag for trending. This shall preferably
an operator function.
13.4.5.2. Facility to trend any variable; analog / digital,
intermediate computed value, etc.
13.4.5.3. Facility to view a minimum of four variables on a
common time axis.
13.4.5.4. Assign different sampling frequency and time interval
for viewing each variable.
13.4.5.5. Zooming of Y axis and scrolling of time axis.
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13.4.5.6. Reading instantaneous value of a variable at a given
time by positioning the curser at that point on time axis.
13.4.5.7. Trending of one variable against some other (X-Y
plots).
13.4.5.8. It shall be possible to view all trended variables from
any OS.
13.4.5.9. Facility to group/delete a variable from a group. This
should be an operator function.
13.4.5.10. Scrolling of time axis on X- axis and scrolling of range
on Y axis. Tag no., alarm status and the dynamic value of
the variable in digital form on the trend page.
13.4.5.11. It shall be possible to trend any variable, analog or
digital and any parameter of any particular tag.
13.4.5.12. For an analog tag it shall be possible to trend PV, SV,
MV deviation, ratio or any intermediate calculated value in
a algorithm and any standard block parameter.
13.4.5.13. Maximum Sampling Time For Any Trend Shall Be 1s
or less. It shall be possible to assign different sampling
times tag wise independently without any limitation with
user configurable DB.
13.4.5.14. It shall be possible to store all trends for long time
historian without any time limit on retention period, except
the hard disk size. If diff. operator stations are storing trend
data of diff. trend group, all these stations shall be equipped
with min. 2TB RAID-5 SSD. It shall be possible to dump
data older than 120 hours automatically to a data storage
device like RAID-5 SSD folders and from which it can be
retrieved for viewing at later date.
13.4.5.15. BIDDER to give more details regarding data storage
and retrieval.
13.4.5.16. On-line archiving of trends shall be possible. Real time
trends of 2 hours time base shall be generated perfectly
from the control stations. This should not need any history.
In case of power failure, no loss of real time, historical and
trend data shall occur.
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13.4.6.
SPECIFICATIONS FOR
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Graphic Displays
These shall be used most frequently by the operators for plant
control and monitoring and shall have the following features:
13.4.6.1. Graphics shall be fully dynamic and interactive.
Animation facility shall be available. BIDDER to inform the
maximum number of dynamic targets any display can
accommodate.
13.4.6.2. Library of frequently used pictures / symbols. Facility
to build user defined symbols and store the same in the
library.
13.4.6.3. Windowing of any graphic in to any other display and
vice versa. Zooming of an object.
13.4.6.4. Overlays feature shall be provided to superimpose
windows of various types and sizes on a graphic. The
overlay can be a face plate of a loop, a part of any graphic,
a trend, a message etc. It should be possible to have more
than one overlay of different type on any graphic and they
all are should be freely movable within main graphic
window.
13.4.6.5. BIDDER have to specify the maximum numbers of
overlays of different sizes, opened on a standard base
graphics and any other limitations.
13.4.6.6. Font size shall be freely configurable.
13.4.6.7. Background colour of graphic shall be freely
selectable. .
13.4.6.8. Graphics builder shall have all ISA symbols in library
form, so that standard, uniform graphics can be generated
in a less time.
13.4.6.9. It shall be possible to assign at least 4 modifier
conditions to a graphic character/object. By modifier
conditions it is meant change of colour, size, filling &
visibility of a pattern etc.
13.4.6.10. Graphic builder package shall be easy to operate
without any detailed knowledge of hardware/software. In
particular following features are desirable:
13.4.6.11. It shall be possible to build graphic through “touch
screen” and mouse. All features of interactive menu driven
graphic builder like drag and drop , edit , copy , paste with
on line program sensitive help shall be available.
13.4.6.12. Software shall have facilities to change/modify either
at a global level or discrete level and the same can be
updated in all places with minimum key strokes.
.
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13.4.6.13. Graphic builder package shall have command / script
support for complex graphic which can manipulate control
strategy.
13.4.6.14. Facility to “zoom” a picture for better visibility shall be
available.
13.4.6.15. Security features like masking / access lock shall be
available for graphics or parts thereof.
13.4.6.16. It shall be possible to save pictures or parts thereof in
the symbol library (to be used again) directly from the
picture being drawn & the same need not be drawn once
again for the purpose.
13.4.6.17. 60% of total nos. of analog I/O at 500msec scan time.
13.4.6.18. 40% of total nos. of closed loop at 250 msec. time.
13.4.6.19. 40% of total nos. of digital I/O at 10 msec. time.
13.4.6.20. 10% of total nos. of digital I/O at 1 msec. time.
13.4.7.
System Configuration Displays:
13.4.7.1. These shall be generated automatically by the system
software parallelly as the application software is developed.
These shall be live displays and show different process
parameters of a loop, intermediate computed values in
complex loops, logic execution, sequence execution, etc. in
a dynamic form.
13.4.7.2. These shall be used for configuring a loop and shall be
mainly used by engineer. These should also be dynamic
and should show the various loop intermediate parameters
in the loop in digital form. (e.g. a temperature indicating loop
should display the mV signal being received, the value after
conversion to temperature units and so on).
13.4.7.3. It shall be possible to effect “on line” configuration
changes using these displays.
13.4.7.4. Online changes made in the controller sub system,
shall not affect the output of a closed loop or process.
BIDDER to categorically clarify the limitations if any.
13.4.7.5. Changing of units, ranges, alarm values, dead bands,
alarm priority, linearization etc. Of one I/O shall not affect
the others. The last good values hold feature shall be
implemented in the system with alarms.
13.4.7.6. The access to these displays shall be protected by key
lock switch and/ or a password.
13.4.7.7. It shall be possible to log any tag, calculated results or
any block standard parameter in the freely formatted
manner and log scheduling shall be t user defined interval
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Page 51 of 124
or on demand. BIDDER to specify the total nos. of
log/reports and total point per log limit. Elementary
calculations like min., max., averaging, addition,
subtraction, rounding off, division, etc. shall be possible in
the free format logs with time and date functions. It shall be
possible to transfer all these type of reports/logs in a simple
ASCII format in a storage media automatically.
13.4.7.8. High level programming language support The system shall provide proper and secure facilities for
developing, modifying, compiling and running of user
written programs in any high-level language like C, C++, VB
or any other 3rd party optimization package etc. It shall be
possible to modify, compile and download the program
without affecting the normal controller operation. BIDDER
to specify the residency and run time platform of these
programs. If it requires any extra hardware, then BIDDER
to quote for the same with full technical details and
limitations.
13.4.8.
System Diagnostic Displays
13.4.8.1. These shall be used to detect system faults and
quickly determine a malfunctioning node of the system.
These shall be dynamic and interactive and arranged in a
hierarchical fashion to trace a fault up to module level.
13.4.8.2. These shall be arranged in a hierarchical fashion such
that a fault in any of the units of the system can be traced
upto module level by suitable annunciation. Modules and
individual channel level fault diagnostics with immediate
alarms on all operator stations are a must. The following
information shall be available through these displays as a
minimum.
13.4.8.3. BIDDER to explain the various diagnostic
features/facilities/to stays available in the system including
maintenance procedures and following information.
13.4.8.3.1.
13.4.8.3.2.
Type and location of malfunctioning unit.
Nature of fault.
13.4.9. All readouts and graphic displays shall be in S.I. units and
all symbols as per ISA respectively and in English. Proper colour
codes, graphic density etc. shall be as per OWNER’s requirement.
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13.4.10. The graphical user interface (GUI) shall follow advanced
industrial software & hardware standards as far as possible. In
case of using Workstation - based operator and engg. stations the
GUI shall follow industrial standards. System shall be able to
handle instrument tag numbers consisting of minimum 12
characters.
13.4.11. Display call up time for various displays shall be a maximum
of 1 second irrespective of displays’ total dynamic I/O points,
density. BIDDER to specify the display updates times.
13.5. Peripheral Devices
Peripheral devices are printers, copiers etc. which are used to take print-outs
of alarms, logs, display screens. The quantity of these shall be as per the
system architecture attached with the specification.
13.5.1.
Colour Printer with Scanner & Copy / Xerox:
This shall be used for purpose of taking print-out of graphic
pages / any other screen print-outs, logging reports, etc. Following
specifications shall govern:
13.5.1.1. Type: Ink-jet type LAN printer
13.5.1.2. Paper size: A3 / A4 combined printer
13.5.1.3. Double sided printing
: Required
13.5.1.4. Memory
: 2GB min
13.5.1.5. Interface with OS / ES
: Accessible to any OS / ES
through printer LAN
13.5.1.6. COPY / XEROX
: Required
13.5.1.7. Colour Scanning
: Required
13.5.2. Black & White Printer
This shall be used for printing of alarms / operator logs and will
have the following specifications:
13.5.2.1. Type : Laser type LAN printer
13.5.2.2. Paper size : A3 / A4 combined printer
13.5.2.3. Print out
: Page-wise
13.5.2.4. Double sided printing
: Required
13.5.2.5. Memory
: 1GB min
13.5.2.6. Interface with OS / ES
: Accessible to any OS / ES
through printer LAN
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13.6. Multi-loop Controllers and Data Acquisition System
These shall be used for closed loop control / data acquisition. This shall also
have capabilities to execute process sequences and interlock logic. It shall
have full peer to peer communication with all other system nodes.
➢ Control, logic and sequence functions shall be executed
through standard function blocks linked together using drag /
drop techniques and assigning tag numbers. No special higher
language programming be required for the purpose. The
necessary builder package shall support all the languages
recommended by IEC 61131.
➢ The system shall have the capability to build user defined
control / monitoring blocks, logic / sequence blocks, or a
combination of these; and store the same under a given name,
for repeated use in future.
➢ All analog inputs shall be isolated with current limiting circuit to
guard against short circuit / accidental grounding of field wires.
➢ wire transmitters shall be powered from active barriers and if
no barriers are used, through the analog input card / signal
conditioning hardware.
➢ Digital inputs and outputs shall be isolated. Isolation shall be
galvanic / optical.
➢ The number of inputs / outputs per module shall be restricted
to the following maximum:
❖ Analog inputs : 8
❖ Analog outputs : 8
❖ Digital inputs
: 32
❖ Digital outputs : 32
❖ Pulse inputs
:8
❖ RTD inputs
:8
❖ Thermocouple inputs : 32
➢ A / D conversion shall have a resolution of 16 bits
minimum. D / A conversion shall have a resolution of 12
bits minimum.
13.6.1.
Functions Supported
Following functions shall be supported by the system as a
standard. At start of engineering phase vendor shall furnish library
of standard blocks available in the system elaborating their features.
13.6.1.1. Control & Monitoring Functions
13.6.1.1.1. PID, PID with external bias, PID on-off, PID gap, PID with
cascade and ratio, PID with adaptive gain and reset.
13.6.1.1.2. Self-tuning
13.6.1.1.3. Lead / lag compensation
13.6.1.1.4. Dead time compensation
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13.6.1.1.5. Pressure and temperature compensation for flow
13.6.1.1.6. Pulse input scaling
13.6.1.1.7. Integration / totalising (resettable and non-resettable
counters of 6 digits minimum)
13.6.1.1.8. Velocity limiter
13.6.1.1.9. Ramp generation
13.6.1.1.10. Cold junction compensation for all types of thermocouples
13.6.1.2. Mathematical & Computing Functions
13.6.1.2.1. Addition, subtraction, multiplication, division, square, square
root
13.6.1.2.2. Piecewise linearisation
13.6.1.2.3. Moving average
13.6.1.2.4. Elapsed time computing
13.6.1.2.5. Absolute value
13.6.1.2.6. High / low / median / average value selection
13.6.1.2.7. Comparator (> , <, =, etc.)
13.6.1.2.8. Exponential, logarithmic functions
13.6.1.3. Logic Functions
13.6.1.3.1. AND, OR, EX-OR, Inverter
13.6.1.3.2. Flip-flops of all types
13.6.1.3.3. Timers (on-delay / off-delay, settable up to 24 hours)
13.6.1.3.4. Rising edge / falling edge trigger
13.6.1.4. Sequence Functions
13.6.1.4.1. System shall support Sequential Function Chart (SFC)
function as per IEC 61131 / ISA SP-88 recommendations.
13.6.1.5. Database Support
13.6.1.5.1. Commonly required data like steam tables, T/C characteristic
tables, etc. shall be available as a standard.
13.6.2.
Inputs / Outputs
System shall support the following inputs / outputs as a
minimum:
13.6.2.1. Analog Inputs
13.6.2.1.1. 4~20 mA DC HART, active and passive. Input resistance 250
Ω maximum.
13.6.2.1.2. 1~5 V / 0~10 V DC. Input resistance of 10 MΩ minimum.
13.6.2.1.3. Pt 100, 2 / 3 / 4 wire RTD input as per IEC 751.
13.6.2.1.4. Thermocouples of all types as per IEC 584-2
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13.6.2.2. Analog Outputs
13.6.2.2.1. 4~20 mA DC with permissible load resistance of 750 Ω
minimum.
13.6.2.2.2. 1~5 / 0~10 V DC, into load resistance of 10 kΩ minimum.
13.6.2.3. Digital Inputs
13.6.2.3.1. Potential free contacts, momentary (10 ms pulse) and latched
type.
13.6.2.3.2. Transistor open collector, PNP and NPN type.
13.6.2.3.3. All proximity sensors as per NAMUR standards.
13.6.2.3.4. Pulse train, frequency 0~10 kHz minimum, powered and nonpowered.
13.6.2.3.5. Digital inputs from MCC/ Switchgear shall be wired through
PCB mounted interposing relays for isolation.
13.6.2.4. Digital Outputs
13.6.2.4.1. Digital outputs to all loads shall be through PCB mounted
interposing relays.
13.6.2.4.2. The system shall support both latched and pulsed outputs. In
case of pulsed outputs, it shall be possible to have both positive and
negative pulse. Pulse width shall be adjustable individually from
1~60 seconds.
13.6.3.
Scan Rates
It shall be possible to assign scan rates to all loops and logic
individually. By definition scan rate means the time taken to read
the input, linearisation and A/D conversion of the same, performing
control algorithms and outputting the result including D/A
conversion. Following requirements shall be applicable:
13.6.3.1. Closed control loops flow, pressure
: 500 ms
13.6.3.2. Closed control loops level / temperature and
monitoring loops flow /pressure: 1 s
13.6.3.3. Monitoring loops for level, analysis, temperature
:2s
13.6.3.4. Interlock logic
: 500 ms
13.6.3.5. Vibration
: 100-500 ms**
13.6.3.6. **: This shall be finalized in consultation with vendor’s
specific guideline if Vibration Transmitters are used &
tripping interlock is implemented in DCS.
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13.6.4.
Redundancy Requirements
Redundancy requirements at various levels are as follows:
13.6.4.1. Analog inputs / output modules for closed control
loops: 1:1
13.6.4.2. Analog input modules for monitoring loops: Not
required
13.6.4.3. Digital input modules
: Not required
13.6.4.4. Digital output modules
: Not required
13.6.4.5. Pulse input modules
: Not required
13.6.4.6. Serial Input modules
: Ref. Annexure
13.6.4.7. I/O communication modules with CPU : 1:1
13.6.4.8. I/O power supply modules : 1:1
13.6.4.9. CPU for control, I/O communication, network
communication: 1:1
13.6.4.10. Power supply for all CPUs : 1:1
13.6.4.11. I/O bus between CPU and I/O
with all necessary
hardware : 1:1
13.7. COMMUNICATION NETWORKS
13.7.1. This shall mean all the hardware and software needed for
communication between different system nodes as well as devices
within a node. In general, this can be classified broadly in to
following categories:
13.7.1.1. Central data highway on which the different system
nodes shall communicate.
13.7.1.2. Internal communication bus on which different
intelligent devices within a node shall communicate.
13.7.1.3. Communication between a node and a third-party
device, printer, etc.
13.7.2.
Central Data Highway
This is the central network used by all system nodes to
communicate with each other and hence is the most important
communication network. It shall have the following requirements:
a. This shall be a 100 % redundant network (both hardware and
software) for operational security. The system diagnostic
display shall indicate the status of active and standby
highway at any given time.
b. In case of failure of active high way the redundant one shall
take
over
communication
functions
automatically,
instantaneously and smoothly without any loss of
communication.
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c. The health of both the highways shall be checked
continuously and faults annunciate through a system alarm.
d. It shall be possible to add or remove a node from the highway
without interrupting the ongoing communication with other
nodes.
e. In case of failure of one or more connected nodes, the same
shall be automatically bypassed. The communication with
other nodes carries on uninterrupted.
f. The communication shall be fast enough so that even during
plant upsets, shutdowns or start-ups, the highway is not
jammed.
g. Each of the highways shall be routed differently to prevent
damage to both in case of an accident.
h. If the entire length of the data highway cable is routed within
a room, the physical medium can be an armoured co-axial
cable. For lengths running outside room (in between different
rooms) the same shall be an armoured fibre-optic cable.
Unarmoured data highway cables shall not be used anywhere
in the network. Refer details of the architecture diagram
enclosed for more details.
13.7.2.1.
Fibre Optic (FO) Cable
FO cable shall be laid in single runs between different
control rooms in a plant without any joints or splices. The
cable shall be designed to withstand plant temperatures up to
700 C minimum.
FO cable shall be provided with water barrier, strain
bearing glass yarn elements, PVC inner sheath, steel wire
armour and with overall sheath of UV resistant PVC.
Minimum two fibres shall be available as spares. In addition,
following minimum requirements shall be met:
13.7.2.1.1. Fibre / cladding: High purity silica glass; make Corning / J
Fibre
13.7.2.1.2. Construction : Graded index of refraction profile, 62.5/125
microns
13.7.2.1.3. Fill Gell / Protection tube: Poly α Olefin / PBT
13.7.2.1.4. Transmission: Multimode
13.7.2.1.5. Light wavelength: 1300 nm or higher
13.7.2.1.6. Attenuation: < 1 dB/km. Available bandwidth ~ 1.0 GB/km.
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13.7.2.2.
SPECIFICATIONS FOR
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Ethernet Switches
Ethernet switches if used shall be redundant, industrial
type, of rugged construction, capable of withstanding
atmospheric conditions as per clause 4 of the specification.
Ethernet switches shall fulfil the following minimum
requirements:
Switches shall be managed type.
Diagnostics of the same up to port level shall be available on
13.7.2.2.1.
13.7.2.2.2.
OS.
13.7.2.2.3. Capability to program a port to control traffic on the same to
prevent devices from being overwhelmed with unwanted data.
13.7.2.2.4. Capability to control bandwidth of each port to prevent one
device from consuming too much bandwidth.
13.7.2.2.5. Assign data priority so that important data is given priority
over other data.
13.7.2.2.6. Provide port security to select which devices can
communicate through the switch. Each port shall be programmable
through ES, with facility to lock (through software), unused ports to
prevent its unauthorized use.
13.7.3.
Internal Communication Bus
This shall be the communication medium between the various
I / O modules and the CPU executing control, data acquisition, logic
execution and other tasks. The requirements of this are in general
the same as given for Central Data Highway. In addition following
requirements shall be met:
13.7.3.1. In case remote I / O modules are connected to this
network the data transfer rate shall be fast enough to ensure
that there is no compromise in scan times specified.
13.7.3.2. If the entire length of the cable is routed within a single
cabinet, the physical medium can bean unarmoured coaxial cable. In case the cable extends beyond one cabinet
in to another in the same room, armoured co-axial cable
shall be used.
13.7.3.3. In case the remote I / O station is located in another
room, armoured fibre optic cable shallbe used for runs in
between the rooms. The fibre optic cable shall have at least
two spare optical fibres. Refer specifications in above and
system architecture diagram enclosed for more details.
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SPECIFICATIONS FOR
DCS
Page 59 of 124
13.7.4.
Communication with Third Party Devices, Printers, etc.
This shall be serial communication type RS-232 / 422 / 485
or Ethernet TCPIP and shall be used for communicating with
peripherals like printers or reading data from third party devices like
PLCs VFDs etc. Specifications of cables used are same as above.
Following additional requirement shall be met:
13.7.4.1. TCP/IP network for printers shall be separate from
DCS communication networks for control. This is to prevent
overloading of these networks with non-control related data.
This network shall not be redundant. However minimum two
Ethernet Switches shall be used in a distributed manner to
connect DCS OS and ES with printers. This is to ensure that
a single switch failure does not bring the total printing
operation to a halt.
13.7.4.2. Communication requirements with third party devices
along with redundancy requirements are spelt out in
Annexure II of this specification
13.8. MARSHALLING CABINETS
These shall be used to terminate all field cables and mount other hardware
like signal conditioning cards, I/O termination assemblies, safety barriers,
signal converters, relays and any other equipment as required. These shall
have the following specifications:
a. Marshalling cabinets shall be self standing type with hinged front/rear
doors and lifting eyebolts. Hinges shall be concealed type. Door
handles shall be flush type. Cabinets shall be provided with magnetic
latches and door locks.
b. It shall be possible to open all the cabinets with a single key.
c. A 100 mm channel base shall be provided at the bottom.
d. Dimensions (especially height and depth) and colour of all cabinets
shall be identical from point of view of good aesthetics. Dimensions
shall be standardised as follows:
I.
Height : 2100 mm including 100 mm channel frame
II. Depth : 800 mm iii Width : 800 /1200 mm. Cabinets of
width 600 mm to be avoided.
e. Colour of cabinets shall be as per vendor’s standard. Preferred choice
is RAL 7035
f. Cable entry shall be from bottom through removable gland plates.
Sufficient space shall be left near the cable entry area for proper
glanding of field cables.
g. All wires shall be routed through covered PVC ducts. PVC ducts shall
be sized liberally to ensure that future wiring can be easily
accommodated without the duct overflowing. Separate ducts shall be
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DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
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h.
i.
j.
k.
l.
m.
n.
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SPECIFICATIONS FOR
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used for intrinsically safe (IS) and no intrinsically safe (NIS) circuits.
Whereas standard duct colour is grey, colour of IS ducts shall be blue.
Pre-fabricated system cables between I/O termination assemblies
and I/O modules shall be terminated through multiway cable transit
blocks. Bunching of these cables and routing them through a single
big cut-out is not permitted.
Internal layout of marshalling cabinets shall ensure that there is no
overcrowding of components and maintenance accesses are properly
provided. Terminal strips shall be easily accessible and ferrules
readable. All components shall be mounted on front and rear surfaces
of the mounting plate. No component shall be mounted on the
sides/doors/gland plates or in the bolting space provided between the
adjacent cabinets.
A safety earth bus bar shall be provided in each cabinet for earthing.
For shields of cables and system earth, separate bus-bars shall be
provided insulated from the cabinet structure. Material of all bus-bars
shall be copper with nickel/chromium plating.
Cabinets and all the components mounted inside them shall be
numbered with rear engraved acrylic / printed labels.
Ventilation fans and louvered openings with dust filters shall be
provided in all cabinets on front/back doors. In case fans are mounted
on top, they shall have canopies to prevent accidental condensation
from AC ducts entering the cabinet.
Every cabinet shall have a monitoring unit which shall monitor stop /
stalled or open circuit condition of ventilation fans as well as cabinet
temperature. Red LEDs shall indicate individual fan failure. An LED
digital display shall indicate the cabinet temperature. A common
potential free contact output shall be available for annunciating any of
the fan faults and high cabinet temperature, on OS.
Fluorescent light fittings (240 VAC) with isolation and door switches
shall be provided (one each in front and rear) for proper illumination.
A common fuse shall be provided to protect against any short circuit.
Incoming two pole MCB shall be provided for each power supply.
Outlet of MCB shall be terminated on busbars from which power to
individual components shall be tapped through two pole MCBs. For
loads with very low power consumption (viz. trip amplifiers, isolators)
fused terminals shall be provided for isolation. MCBs shall be used
only for rated currents 1A and above. Looping of wires for distribution
of power is not acceptable.
Quantity of marshalling racks shall be frozen only after final approval
of layout drawings during detail engineering.
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SPECIFICATIONS FOR
DCS
Page 61 of 124
13.8.1. Wiring
13.8.1.1. Wiring shall be done using PVC insulated wires 660 V
grade.
13.8.1.2. All wires shall be provided with hot stamped ferrules
with black letters on white background. The ferruling
philosophy shall be self + cross.
13.8.1.3. The size and colour coding for wires to be used within
the cabinets is as follows:
Sr. No.
Type Of Signal
Conductor Cross Section
Colour Code
Wiring colour code to be
finalised during detail
engineering.
1.
4~20 mA, input / output
0.75 mm2
2.
Digital Inputs
0.75 mm2
3.
Digital Outputs
4.
RTD Inputs
0.75 mm2
5.
T/C Inputs
16 AWG / 20 AWG
6.
230 VAC Power Supply
As per load requirements
7.
24 VDC Power Supply
As per load requirements
As per driven load
13.8.2. Terminals
13.8.2.1. Terminals shall be single tier type. Multi-tier
terminals shall not be used. Following specifications shall
govern:
➢ Make
: Phoenix / Weidmuller
➢ Material : Polyamide
➢ Size :2.5 mm2. For power supply wiring, the size shall be
as per requirements.
➢ The different types of terminals to be selected is as per
the following philosophy:
• Analog inputs, active and passive : push through type
• Analog outputs
: push through type
• DI: Fused in both legs with LED indication push
through type
• DO: Fused in both legs with LED indication push
through type
13.8.3.
Relay Boards for Digital Inputs and Outputs
These shall be used for digital inputs from electrical
switchgear and all digital outputs. The wiring of relay boards with
DI/DO modules shall be preferably through prefabricated cables.
Relay boards shall be mounted on DIN rails. The brief specifications
are:
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SPECIFICATIONS FOR
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Page 62 of 124
13.8.3.1. Relay type: Plug in, coil voltage 24 V DC ± 10%; coil
to be provided with freewheeling diode.
13.8.3.2. Service life : At least 2 million cycles at rated
conditions.
13.8.3.3. Contacts
: Sealed, 2 NO/NC changeover type;
both contacts to be wired up to terminals.
13.8.3.4. Contact rating: 240V AC, 10A @ worst PF 0.3 lagging;
24V DC TO 110 V DC, 10A
13.8.3.5. LED indication: Required. LED lights up when relay is
energised.
13.8.4.
Other Miscellaneous Requirements
13.8.4.1. The internal layout of the marshalling cabinets shall be
such that at site, after erection, only pre-fabricated cables
need to be laid from marshalling cabinets to system
hardware cabinets; thus, saving valuable time. To achieve
this, the signal conditioning hardware, relays, barriers, etc.
shall be mounted in marshalling racks.
13.8.4.2. All field terminations shall be done on a terminal strip
only and not directly on any other hardware.
13.8.4.3. Terminal strip blocks shall be arranged as per JB
termination (including spare cores / pairs) to achieve 1:1
correspondence with JB termination. JB number shall be
affixed along with the terminal block number
13.9.
SYSTEM HARDWARE CABINETS
These shall be used to mount the system hardware like the
CPU and communication hardware, I/O modules etc. The colour and
dimensions shall be same as those of marshalling cabinets. All other
specifications remain identical to those of marshalling cabinets given
as per 8.8. The quantity of system cabinets shall be frozen only after
final approval of internal layout during detail engineering.
13.10.
POWER DISTRIBUTION CABINETS
These shall be used to mount the hardware required to distribute
power at various voltage levels to DCS consumers as well as to field
mounted instruments. These shall have the following minimum
requirements:
13.10.1. Dimensions and colour shall be identical to those of
marshalling cabinets / system cabinets.
13.10.2. Different cabinets shall be used for different voltage levels. In
case the number of feeders for a voltage level are less to justify a
separate cabinet, more than one distribution can be combined in
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SPECIFICATIONS FOR
DCS
Page 63 of 124
to one cabinet. In such a case geographical separation shall be
maintained by separating the distribution to front and back side of
a cabinet, providing isolating barriers between the distributions,
etc.
13.10.3. Incoming isolation shall be through a double pole MCB for
rating ≤ 60 A, else a MCCB shall be used. Alternatively, a double
pole switch with HRC fuses can be used. Further distributions shall
be through busbars and double pole MCBs as in marshalling
racks. No looping shall be done. MCCBs / MCBs used for DC
service shall be suitably derated as per manufacturer’s
recommendations.
13.10.4. Following indications are required.
13.10.4.1. Incoming “AC Power On’ lamp. Three separate lamps
(one for each phase) in case of 3Φsupply.
13.10.4.2. Digital voltmeter for incoming AC supply (with a threeposition selector switch to read individual phase voltage in
case of 3Φ supply).
13.10.4.3. Digital ammeter for incoming AC supply (with a threeposition selector switch to read individual phase current in
case of 3Φ supply).
13.10.5. The rating of MCBs shall be as finalised during detail
engineering. The ratings of individual MCBs, and incomer shall be
co-ordinated with the overall power distribution scheme to avoid
spurious trips. Vendor shall submit a consolidated document giving
the characteristic curves of MCCBs, MCBs and fuses used by him;
calculation of co-ordination with overall power distribution scheme,
etc. for ICS approval.
13.10.6. The terminals for field wiring shall be chosen as per the size
of cable to be terminated and shall be finalised during detail
engineering. Sufficient space shall be reserved for this to
accommodate bigger size aluminium cables.
13.10.7. All other specifications are identical to those for marshalling
cabinets given in section 13.8.
13.10.8. Quantity of power distribution cabinets shall be frozen only
after internal layouts are approved during detail engineering.
13.11.
CONTROL ROOM FURNITURE
13.11.1. Operator Console
I.
Operator consoles shall be used to mount operator station
PCs, screens, keyboards, mouse, paging system, telephone
handsets, etc. Auxiliary consoles shall be used to mount other
hardware like push buttons, lamps, annunciators, etc. Operator
consoles and auxiliary consoles shall be similar in appearance
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DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
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II.
III.
IV.
V.
VI.
SPECIFICATIONS FOR
DCS
Page 64 of 124
and dimensions so as to form a single, smooth, continuous,
unit. Corner consoles shall be considered as required.
Consoles shall be ergonomically designed keeping in mind
comfort level of operator, minimum eye strain and good
aesthetics. PCs for operator stations shall be kept in closed
lockable compartments below the table top. Compartments
shall be provided with ventilation fans and louvers with dust
filters. A common fan failure/high temperature alarm shall be
available on OS per compartment similar to marshalling rack.
Console framework shall be extruded aluminium or MS
members. Table top shall befabricated from compacted
medium density fibre board. Finishing shall be of high quality
laminate / scratch resistant acrylic.
Each console shall have its dedicated power supply distribution
arrangement. All power andsignal wiring shall be done in
closed metal / PVC ducts.
OS screen and keyboard mounting shall provide for adjustment
of elevation and inclination.
Console shall be designed to meet following requirement:
➢ No. of OS with dual tier screens
: 4 nos.
➢ No. of OS with single tier screens :1 nos.
➢ Printers / copiers
: 2 nos.
13.11.2. Engineering Console
I.
Engineering Console shall be used to mount engineering
station PC, screens, keyboard, mouse, etc.
II.
The general constructional features shall be similar to those
of operator console ii – v above.
III.
Engineering station printer and the portable CD/DVD
Combo drive shall be kept on the same console and the
table top shall be big enough to accommodate the same.
Lockable storage compartments shall be provided to store
system CDs.
13.11.3. Printer Tables
13.11.3.1. Printer tables shall be used to mount printers.
13.11.3.2. These shall be self-standing type with power supply
distribution arrangement and provided with shelves to store
printer stationary.
13.11.3.3. Vendor’s standard design is acceptable.
13.11.4. Operator Chairs
13.11.4.1. Operator chairs shall be designed for maximum
operator comfort and reducing fatigue considering long
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SPECIFICATIONS FOR
DCS
Page 65 of 124
hours of work. They shall be provided with soft cushions,
adjustable armrests, back inclination and seat height.
Castors shall be provided to enable rolling of the same on
floor with ease.
13.12.
INTERCONNECTING CABLES
These shall be used for interconnection between different cabinets
when the same are located apart (not bolted together). Following
specifications shall hold:
Sr. No.
Cable Type
Cable Specification
1.
Signal cables for analog I/O, 0.75 mm2 multi-stranded tinned copper conductor, PVC
insulated, twisted pair/triad, overall screened, PVC inner
digital inputs, RTD inputs
sheath, armoured, PVC outer sheath; 6/12 pair, 8 triad.
660 V grade.
2.
T/C extension cables
3.
Cables for digital outputs
4.
Power supply cables
5.
Modbus cables
6.
Central
data
Ethernet cables
7.
Internal data highway cables
Vendor’s standard specifications shall govern.
8.
Pre-fabricated system cables
Vendor’s standard specifications shall govern.
9.
Fibre Optic cables
for detailed specification REFER ABOVE
Conductor material same as thermocouple, size 16 AWG,
PVC insulated, twisted pair, overall screened, PVC inner
sheath, armoured, PVC outer sheath; 6/12 pair. 660 V
grade.
1.5 / 2.5 mm2, multi-stranded tinned copper conductor,
PVC insulated, PVC inner sheath, armoured, PVC outer
sheath; 12/24 core. 660 V grade.
3 core solid tinned copper conductor, (size of conductor as
per requirements of load), PVC insulated, PVC inner
sheath, armoured, PVC outer sheath. 660 V grade.
Armoured, as per applicable std.
highway Armoured, co-axial type as per vendor’s standard
specifications.
All interconnection cables shall be glanced at both ends with double
compression type SS304 cable glands with PVC hoods.
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SPECIFICATIONS FOR
DCS
Page 66 of 124
14.
BOUGHT OUT ITEMS INCLUDED IN VENDOR’S SCOPE OF SUPPLY
Following items are included in scope of supply of the vendor. The makes of
these items shall be strictly adhered to and concurrence of INDORAMA ICS
shall be taken before purchasing these from alternative sources. INDORAMA
ICS reserve the right to reject / accept any vendor suggested by the vendor.
Model numbers of each item shall be frozen during detail engineering.
Sr. Description
Acceptable Makes Qty. incl. Remarks
No.
spares
1.
Safety barriers analog
MTL, P &
Active, HART pass
input
F
through
2.
Safety barriers analog
MTL, P &
Active, HART pass
output
F
through
3.
Safety barriers/Isolator MTL, P &
digital inputs ( NAMUR) F
4.
Safety barriers digital
MTL, P &
outputs
F
5.
Safety barriers FF
MTL, P &
signals
F
6.
RTD
to
Current MTL, P &
136
Active type
Converter for RTD F
Inputs
7.
Safety barriers T/C
MTL, P &
Active type
inputs
F
8.
Analog Input Signal
MTL, P &
63
HART pass through
isolators
F
9.
Analog Output Signal
MTL, P &
20
HART pass through
isolators
F
10. Isolator
digital
MTL, P &
4
inputs ( NAMUR) F
11. Trip amplifiers
MTL, P
& F,
HART pass through
Yokogawa,
12. Signal converters
Yokogawa
HART pass through
13.
Earth Fault Detector
14.
µP based recorders
Chino, Yokogawa
-
15.
µP based One Loop
Controllers
Sequence of event
recorder
Chino, Yokogawa
-
Hathaway
-
16.
Vendor to suggest
Mounted
console
Mounted
console
Mounted
console
on
auxiliary
on
auxiliary
on
auxiliary
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SPECIFICATIONS FOR
DCS
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
17.
Alarm annunciators
Minilec
18.
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Mounted
console
on
auxiliary
Bulk power supplies 24 Phoenix, Cosel,
V DC
TRC Electronics
(Mean Well)
19. 230 VAC to 110
ABB/ Siemense or
VAC
equivalent
transformer
20. Diode ORing unit
Phoenix,
TRC
Electronics
(Mean Well)
21. Portable CD/DVD read Sony, Samsung
/ write drive
22. FF junction boxes with MTL, P&F
barriers or segment
protectors
Sr.
Description
Acceptable
No.
Makes
23. Network Switches
Cisco, Siemens
As
required
24. Printers, Copiers
HP, Canon
25. Push buttons
Paramount,
Siemens,
Technic,
26. Key switches
Paramount,
Siemens,
Technic,
Paramount,
Siemens,
Technic,
Paramount,
Siemens,
Technic,
J yoti, Omron,
Paramount
1 Colour + 1 Black &
white
on
15 (Hold) Mounted
auxiliary console
Mushroom type 5 Nos
+
latch type 10 Nos
Mounted on auxiliary
console
27. Selector switches
28. Indicating lamps
29. PCB mounted relays (
mounted on on relay
board, relay board DIN
rain mounted) with 2
changeover contacts
As
110 VAC required for
required existing solenoid valves.
As
required
Material
SS/Polycarbonate
Qty. incl.
spares
As
required
2
Remarks
5 (Hold)
Mounted on auxiliary
console
15 (Hold) Mounted on auxiliary
console
600
Coil Voltage
24VDC. Contact
rating 230 VAC,5A &
24VDC, 3A.
262 (DI) +338(DO),
Qty Hold to be
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SPECIFICATIONS FOR
DCS
Page 68 of 124
finalised during detail
engineering.
30. Relay boards with relays
UL
31. Contactors
Schneider,
Siemens, L&T
MDS, Siemens,
Standard Kupp
32. MCBs double pole of
different ratings
33. MCCBs
34. Voltmeters, Ammeters,
CTs
35. Cabinets of all kind
36. OS/ES consoles
37. Printer / copier tables
38. Operator chairs
39. Multi-way cable transit
blocks
Sr.
Description
No.
40.
FO cable
Alsthom,
Siemens
AE
L&T,
Hoffman, Rittal
Cosmos Knurr,
Pyrotech
Vendor’s
standard
Godrej,
Pyrotech
Bradburg /
Roxtec
Acceptable
Makes
Finolex, Birla
Ericsson
10
6
Approved makes of
relays:
Omron,
Paramount,
Honeywell
For HT Motors
These are for powering
field
instruments.
Other’s required within
DCS panels shall be
decided by vendor.
Exact rating of each
shall be given during
detail engineering.
As reqd
As reqd
As reqd
to meet
specificati
ons
Separate cabinets for
AI/AO , DI & DO.
Panelwise segregation
for 230/110 VAC & 24
VDC to be kept
2
3
As reqd
Qty. incl.
spares
As reqd
Remarks
Operator
Stations
will
be
located
approx. 100 mtrs
from Rack room, in
separate building
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DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
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41.
15.
Modbus, Profibus,
Fieldbus Cable
Belden,
Kerpen
As
Required
SPECIFICATIONS FOR
DCS
Page 69 of 124
Refer DCS Serial
Link
requirements
for
length
calculations. Cable
supply by vendor
INSPECTION
Inspection of the system shall be carried out in two stages:
Pre-Factory Acceptance Test (Pre-FAT) Final FAT
15.1. Pre-FAT
Pre-FAT shall be carried out to assess the overall preparedness of the
vendor for final FAT. Following shall be checked:
I.
Availability of all hardware and assess shortfall if any.
II.
Completeness of all panels and consoles as regards
mounting of components & hardware, labelling, wiring,
ferruling, etc. (random sampling).
III.
Completeness of software generation as regards tag data
base, graphics (static and dynamic), loop configuration,
interlock generation, sequence generation, etc. This activity
shall be done on random sampling basis.
IV.
General adherence with philosophy and approved
documents to ensure that no common mode mistakes,
omissions, are noticed later during FAT. This shall be
checked on random sampling basis.
The final date for final FAT shall be mutually decided after pre-FAT is
complete; INDORAMA ICS is reasonably satisfied about progress of work;
and FAT can be carried out without loss of time of clients and INDORAMAIndia.
Cost of pre-FAT shall be borne by the vendor.
15.2. Final IFAT
I.
II.
III.
IV.
Vendor shall give a minimum notice of 3 weeks to
INDORAMA ICS for final FAT of the system at vendor’s
works.
Cost of inspection / testing shall be borne by the vendor.
It is expected that vendor has completed all the in-house
QC checks on the system. This includes not only standard
checks on hardware but also checks on bought out
components, complete application software, internal wiring,
and so on. Vendor shall confirm in writing that all the inhouse checks are complete and the system is ready for final
FAT.
The entire system shall be staged by the vendor in his
works. The consoles and cabinets shall be assembled in
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SPECIFICATIONS FOR
DCS
Page 70 of 124
exactly the same way as they will be at site. All the
interconnections between cabinets shall be complete,
system hardware shall be in place, all software loaded and
bought-out hardware included in vendor’s scope of supply
duly mounted. Wiring within each cabinet and between
cabinets shall be complete.
V.
Clients / tkIS-India reserve the right to carry out inspection
of any bought out items at the sub-vendor’s works.
VI.
It shall be the responsibility of vendor to arrange all the test
and measuring instruments required during inspection. The
instruments shall have a valid calibration certificate from a
recognised test house and the calibration shall be traceable
to any of the national test houses.
VII.
3rd party package vendors shall participate during FAT for
checking completeness of 3rd party process packages e.g.
Ammonia compressor.
The inspection shall briefly envisage the following:
15.2.1. Hardware Inspection
This shall consist of:
I.
Checks on general workmanship like fabrication
quality, paint quality, paint shade, etc.
II.
Dimensional inspection for base frame, height,
depth, width, etc.
III. Provision of busbars for safety earth, system earth,
IS earth.
IV.
Checks on correctness of all labels.
V.
Power supply wiring and operation checks for fans,
tube lights, utility sockets, etc.
VI.
Power supply and signal wiring checks including
colour code of wires, size of wires, correctness of
ferrules, correctness of wiring termination, wiring
segregation, etc.
VII. Provision of terminals of correct size and type.
VIII. Operation of lamps, push buttons / switches,
MCCBs / MCBs, annunciators, relays /contactors,
ammeters / voltmeters and other instruments
mounted on the consoles or cabinets.
IX.
Megger test for power distribution cabinets.
X.
Checks on correct installation of I/O racks as per
approved drawings and I/O modules within racks as
per nest loading.
XI.
Redundancy checks as per specifications on power
supply, CPU, communication, and I/O modules.
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XII.
XIII.
15.2.2.
SPECIFICATIONS FOR
DCS
Page 71 of 124
Checks on battery back-up on all volatile memory by
switching off power for the duration given in vendor’s
specifications.
Loop checking shall be conducted from graphics
level till marshalling terminals. Detail procedure for
the Loop checking shall be provided by INDORAMA
ICS during detail engineering.
Software Inspection
This shall consist of 100% checks on following:
I.
Checks on generated data base. This includes
checks on correctness of tag number, service
description, measuring range, engineering units,
input signal conditioning, control algorithms
associated with the tag, output signal conditioning,
etc.
II. Graphics shall be checked for static and dynamic
information. This includes checks on correctness of
graphics as per process, line thickness and colour,
correctness of equipment tags and instrument
tags, units of measurement, modifier conditions,
linking between pages, operation of dynamic and
interactive targets, etc.
III. Operation of all keys on the keyboard for their
proper operation.
IV. Printing operations like alarms, operator actions,
log reports, etc.
V. Correctness of tag grouping in group displays and
trend displays, sampling interval for trends.
VI. Alarm priorities.
VII. Special (non-standard) loops shall be checked
100% from input to output for correctness of
engineering.
VIII. 100% checks on all logics and sequences.
IX. Checks on any higher language programs.
X. Communication between any third-party device
and DCS.
XI. After hardware and software inspection is
complete, an exhaustive punch list of all pending,
incomplete jobs, mistakes, etc. shall be prepared
jointly by INDORAMA ICS and vendor. Vendor
shall attend to all the punch list points and certify in
writing to that effect. Dispatch clearance shall be
given only after such a written confirmation is
received.
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DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
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SPECIFICATIONS FOR
DCS
Page 72 of 124
16.
TEST SET-UP REQUIREMENTS
Vendor shall make available the following testing apparatus / hardware
during inspection. No inspection shall be carried out unless the test set up is
ready.
16.1. Switch-bank of 64 switches, push buttons, duly wired; minimum 1 number.
16.2. Lamp-bank of 64 lamps; minimum 1 number.
16.3. 4~20 mA signal generators to simulate two wire and four wire transmitters,
minimum 2 numbers.
16.4. mV generators, decade resistance box; minimum one number of each.
16.5. Pulse generator for testing pulse inputs.
17.
INSTALLATION PRE-COMMISSIONING AND COMMISSIONING
INDORAMA ICS shall intimate to the vendor in writing regarding the
mobilisation schedule of his site staff at site. It shall be ensured by INDORAMA
ICS that control room/s are reasonably completed, free of any debris / dust, doors
and windows are fitted and major civil work is complete before such a request is
sent to the vendor. On receipt of such a request the vendor shall send a team of
experienced engineers, technicians and other erection staff for purpose of
installation, pre commissioning and commissioning of the system at site. The
engineer involved in application software generation shall be made available for
deputation on a continuous basis. Additionally, it is expected that the engineers
deputed to site for the purpose of pre-commissioning / commissioning activities,
have an experience of at least five years with the vendor. Engineers less than this
experience are not acceptable and any delay in site activities on this account shall
be solely attributed to the vendor. Bio-data of proposed site deputees shall be
submitted for INDORAMA ICS approval.
vendor is responsible for the following activities:
Assessment of any damages during transportation and providing necessary
help to the clients for any follow-up action.
Co-ordinate with INDORAMA ICS/site contractor during complete loop /
interlock checking of the plant.
Consolidate all loop checking reports with INDORAMA ICS.
Correction of all drawings to make them ‘as built’.
Provide commissioning assistance for tuning of loops, implement minor
changes in interlocks, graphics, establish third party communication if it couldn’t
be done earlier, etc.
The system erection shall be deemed to be mechanically complete when all
the internal loop / logic and interlock checking activity is complete. INDORAMA
ICS site management shall indicate in writing to the vendor as soon as this activity
is completed. The system is now ready for accepting inputs from plant when the
instrument erection is complete and the pre commissioning and commissioning
activities of the plant are started.
The schedule of pre-commissioning and commissioning activities depends on
a number of extraneous factors such as readiness of control room, availability of
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SPECIFICATIONS FOR
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Page 73 of 124
air conditioning, availability of power, progress of instrument erection, mechanical
readiness of plant to start loop checking activity and so on. All of these may not
be available in exactly the way it is desired. It is therefore expected that vendor is
accommodative and willing to show the flexibility to fit-in his site activities within
the constraints.
17.1. Mobilisation Schedule
Mobilisation of vendor’s manpower for carrying out erection and
commissioning activities shall be as per the following table.
Sr.
No.
1
18.
Activity
All activities up to
internal
loop
checking,
Pre
commissioning and
commissioning
assistance
Number Of
Visits
Expected
Total
Duration
(Days)
3
100
Remarks
FINAL ACCEPTANCE AND WARRANTY
18.1. INDORAMA ICS shall take over the system from vendor after final Site
Acceptance Test (SAT) as given below.
18.2. The integrated system shall run uninterruptedly for two weeks from the date
of commissioning of the whole plant. Any loss of time due to reasons like
power failures, forced shutdowns of the plant, etc.; which are due to no fault
of the vendor shall also be counted as run time. However if any major
software / hardware failure of the system occurs due to which the system or
a part thereof has to be shut down the test shall be carried out afresh on the
system. As soon as four weeks of uninterrupted run of the system is
completed successfully, the SAT is deemed to be complete. For the purpose
of warranty, the above definition of SAT shall prevail.
19.
TRAINING
The vendor shall train INDORAMA ICS engineers in his works. The training imparted
shall be by qualified and experienced staff. It shall be exhaustive and aimed at making
the participants self-reliant for commonly encountered problems and day to day
operations. For training the vendor shall make available as close a model of the
system as the actual system to be installed. Necessary printed literature, instruction
and maintenance manuals, in requisite copies in English, shall be arranged by the
vendor.
It is envisaged that the following activities are covered:
19.1. Maintenance Training
This shall cover the following topics minimum:
I.
System architecture
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DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
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II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
SPECIFICATIONS FOR
DCS
Page 74 of 124
Functions of each subsystem
Hardware in each subsystem
Procedures for loading different software.
Complete application software. This shall cover everything from
basics like generation of the different system nodes, building of
displays, loop and logic building, advanced language
programming, debugging of developed application, etc.
Commonly occurring hardware / software problems and the way
to fix the same.
Diagnostic routines available; their use and interpretations.
Routine preventive maintenance procedures.
Maintenance of peripheral devices like printers.
19.2. Operations Staff Training
This shall be restricted to operation of the system and cover the following
topics minimum:
I.
System architecture
II. Functions of each subsystem
III. Function of each key in the keyboard, various shortcuts.
IV. Generation of various displays.
V. Display hierarchy, access methods for various displays,
switching between different displays.
VI. Control of plant from various displays.
VII. Alarm handling
VIII. Logging software
19.3. Training Requirements
Training requirements to Client shall be as per following table. Number of
days required for each training shall be decided by the vendor as per the
respective course contents given above.
Sr.
Description
No. Of
Persons
Location Of Training
No.
Batches
Per
Batch
1.
Maintenance Training
1
3
Vendor’s works
2.
Operations Staff Training 1
3
Vendor’s works
3.
Client’s Engineers
Training
2
Vendor’s works
1
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DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
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20.
SPECIFICATIONS FOR
DCS
Page 75 of 124
SPARES PHILOSOPHY AND CONSUMABLES
20.1. Installed Spares and Spare Capacity
Installed spares are those which shall be supplied with the system duly
installed and wired up. Following philosophy shall govern.
20.1.1. 20% IO’s shall be offered as spares IO count indicated in
Annexure-I is inclusive of this spare. These shall be supplied with
all the hardware required like signal conditioning and termination
assemblies, pre-fabricated cables, etc. The quantity of I/O nests
shall be decided after considering these spare I/O modules for the
IO’s. In addition, 1 spare I/O nest shall be supplied with power
supply modules, communication modules etc. This shall be
connected to one of the controllers (to be decided during detail
engineering).
20.1.2. The I/O allocation in controllers shall be such that in each
controller minimum one I/O nest can be added in future. I.e., the
controller should not be loaded to its I/O capacity.
20.1.3. The controller CPU loading shall not exceed 60% with the
installed I/O modules (including 20% installed spares in ‘a’ above).
The CPU loading with all the I/Os connected to its capacity, shall
not exceed 70%. The CPU loading shall be checked during SAT.
20.1.4. All bulk power supplies shall be sized such that 30% spare
capacity shall be available for future after powering of installed
hardware including spares.
20.1.5. Ethernet switches shall have at least 20% spare ports for
future use.
20.1.6. The quantity of system cabinets shall be decided considering
the requirements of 22.1.1 and 22.1.2 above.
20.1.7. The quantity of marshalling cabinets required shall be
considering requirements of 22.1.1 and 22.1.2 above and after due
consideration to mount other hardware like barriers, relays, etc. as
per philosophy.
20.1.8. DCS licensed tag software shall have 20% additional tag
capacity for future use. All optional software indicated above shall
have 20% spare tag capacity for future use. 20% spare capacity
after including IO’s after special requirements.
20.1.9. The racks shall have FOLLOWING space left as spare so that
cards can be inserted in future. Empty slot shall be covered with
blank plates. For AI/AO = 55% , DI = 25% , DO = 35%
20.1.10. The panels shall have FOLLOWING spare space so that
components like barriers, relays, FTAs, terminals can be mounted
as per future requirement. For AI/AO = 55% , DI = 25% , DO = 35%
20.1.11. Necessary spare quantities are already considered in bought
out items. Hence no spares shall be considered for these items.
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SPECIFICATIONS FOR
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Page 76 of 124
20.2. Commissioning Spares
These are spares required for replacement during erection / commissioning
and till the time of final handing over of the system. Vendor is fully responsible to
ensure that adequate spares are arranged by him at site as and when required, in
shortest possible time, so that the site work is not affected. These spares shall be
supplied free of cost. It is left to the vendor’s judgement to decide which spares
have to be stocked at site and those which can be arranged from the works / subvendors at short notice. Unutilised spares shall be returned to the vendor.
20.3. Two Years Maintenance Spares
Vendor to offer spares as per following guidelines:
20.3.1. For hardware modules which are redundant no spare is to be
considered.
20.3.2. For all non-redundant modules one module of each type to
be considered as spare.
20.3.3. If volatile memory is protected with a battery back-up, 5% of
batteries or one min. to be considered as spare.
20.3.4. 5% of fuses of all types and rating.
20.4. Consumables
Following consumables are required
20.4.1. A4 size paper for laser and ink-jet printer
:1000 sheets
20.4.2. A3 size paper for laser and ink-jet printer
:1000 sheets
20.4.3. Fan-fold printer for dot-matrix printer
:1 carton
20.4.4. Toner cartridge for laser printer :1 no.
20.4.5. Toner cartridge (one of each colour) for colour ink-jet printer
:1 set.
20.4.6. Ribbon cartridge for dot-matrix printer :1 no.
20.4.7. Fuses of all types and rating: 50 nos each
21.
INFORMATION REQUIRED WITH THE BID
Following information is required to be submitted with the bid:
21.1. Technical Details
21.1.1. Point-wise compliance with specifications. Separate
deviation list if any. No deviation taken shall be interpreted as
compliance to specification.
21.1.2. Proven Track Record (PTR). Vendor shall indicate
installations of similar systems and the period for which they are in
continuous operation for more than 2 years.
21.1.3. One-line architecture diagram of the offered system. d
Preliminary drawing of operator console.
21.1.4. Complete bill of material of the system offered including all
spares. This shall be properly segregated sub-system wise.
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SPECIFICATIONS FOR
DCS
Page 77 of 124
21.1.5. List of all licensed software proprietary and bought out along
with the quantity.
21.1.6. Catalogues, technical specifications for all hardware; in
particular for the following:
21.1.6.1. OS/ES
21.1.6.2. Controller CPU/S
21.1.6.3. All types of I/O modules
21.1.6.4. All termination assemblies
21.1.6.5. Communication networks
21.1.6.6. All bought outs
21.1.7. CPU sizing details.
21.1.8. Power supply sizing details.
21.1.9. Expected total power supply consumption and heat
dissipation.
21.1.10. Earthing requirements
21.2. Commercial Details
21.2.1. Cost of hardware and software segregated sub-system wise.
21.2.2. All taxes duties as applicable.
21.2.3. Lumpsum cost for erection up to mechanical completion of
the system
21.2.4. Lumpsum cost for pre-commissioning and commissioning
assistance.
21.2.5. Man-day rates applicable after end of the period stipulated for
pre-commissioning and commissioning.
21.2.6. Rates quoted for activities above shall consider 6 day working
per week with an average of 10 working hours per day.
21.3. Unit Rates for Addition / Deletion
21.3.1. Annexure III gives the rates to be quoted for addition /
deletion. These shall be filled in by the vendor at the time of final
submission of commercial offer. Unit rates shall be filled for all the
items by the vendor. For yellow highlighted items, some notional
quantity against each, is indicated. These items shall not be
ordered but the total value computed for these items (based on
notional quantity and unit rate quoted) shall be loaded in the main
offer to arrive at the final price comparison. For items where no
quantities are indicated, the costs shall not be added for cost
comparison.
21.3.2. Vendor shall indicate the applicable taxes, packing
forwarding and shipment costs to site, separately, for each item.
The unit rates quoted shall be valid till SAT and final acceptance
of the system.
21.3.3. The offer shall not be considered unless the table in Annexure
III is filled by vendor and submitted along with final offer.
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SPECIFICATIONS FOR
DCS
Page 78 of 124
21.4. SPECIAL REQUIREMENTS FOR THE PROJECT
21.4.1. Bidder shall include in cost all engineering changes till IFAT.
No change order shall be raised for any changes in software
engineering till FAT. Hardware changes shall be as per unit rates
quoted as per Annexure III.
21.4.2. No extra claim for any software changes shall be accepted.
Number of graphics & logics shall be provided to fulfil all the
INDORAMA ICS requirements for the operation of plant. DCS
vendor to consider the same.
21.4.3. There are 3 Nos existing ammonia refrigeration compressors
in the plant. This compressor IO count is included in Annexure-I.
Client shall replace these compressors in future. However, the new
compressor IO types will be different than the current IO. Hence in
future client may add related hardware for accommodating these
new compressors IO’s in the same DCS.
21.4.4. There shall be additional space to be provided in the panels
in addition, for mounting hardware components e.g., IO modules,
TB’s, relay boards, Isolators, IO nests, Bulk power supply, NW
switches etc.
21.4.5. However, software & CPU requirements to be considered
now itself for above mentioned IO count.
21.4.6. AI/AO IO cards shall be HART Passthrough.
22.
SR.
NO.
1.
2.
3.
4.
5.
DOCUMENTATION REQUIREMENTS
DOCUMENT
FOR INFORMATION AFTER
PO/LOI
FOR APPROVAL AFTER
PO/LOI
TIME
COPIES (PRINTS )
SCH.
WEEK INDORAMA ICS
TIME
COPIES (PRINTS)
SCH.
WEEK INDORAMA ICS
FINAL
COPIES
S
(1)
P
(1)
Architecture (one line
diagram of the offered
system
Detailed bill of material up
to module level
1
1S
1
6
2
1S
1
6
Bill of material with
catalogues for bought
out items
Proposed
organization
chart for project
execution
Detailed project schedule
2
1S
1
6
1S
1
6
1S
1
6
2
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DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
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6.
7.
8.
Standard dimensional
and layout drawings
for: ❖ Operator
consoles ❖ Auxiliary
consoles ❖ All
cabinets
Calculation
of
total
power requirements at
different voltage levels
Calculation
of
heat
Dissipation
SPECIFICATIONS FOR
DCS
Page 79 of 124
3
1S
1
6
3
1S
1
6
3
1S
1
6
9.
Earthing scheme
3
1S
1
6
10.
Nest
4
1S
1
6
11.
Logic drawings
6
1S
1
6
12.
System tag data base
6
1S
1
6
13.
Print outs of graphics
6
1S
1
6
14.
Typical loop schematics
6
1S
1
6
15.
Final loop drawings
10
1S
1
6
16.
Loading calculations for:
❖ Controller CPU’s
❖ Communication
Networks
6
1S
1
6
loading and
i/o assignment
FOR INFORMATION AFTER
PO/LOI
SR.
NO.
DOCUMENT
17.
FAT procedure
18.
Standard
system
Documentation available
like:
❖ Installation and
instruction manual
❖ Software ref.
manual
❖ Algorithm library
❖ Any other
TIME
SCH.
WEEK
COPIES (PRINTS )
INDORAMA
ICS
FOR APPROVAL AFTER
PO/LOI
TIME
COPIES (PRINTS)
SCH.
WEEK INDORAMA ICS
12
FINAL
COPIES
S
(1)
P
(1)
1S
1
6
1S
1
6
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DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
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22.1.1.
SPECIFICATIONS FOR
DCS
Page 80 of 124
Abbreviations:
S : Soft copies (.pdf files)
P : Prints
22.1.2. Notes:
22.1.2.1. For Vendor documentation, wherever review/approval
is specified, soft copy shall be sent to INDORAMA ICS
Once the document is reviewed / approved, final sets of
documents shall be sent to INDORAMA ICS office for
further compilation as per address mentioned in Purchase
order. These shall not be dispatched to site directly.
22.1.2.2. Drawings to be submitted for approval shall be
submitted as per timeline indicated above and in line with
order specifications. Any deviations with respect to order
specifications shall be listed separately. In absence of
same, order specification will be governing document. It is
vendor responsibility to get drawings approved and if
required vendor to visit Client office to get drawings
approved. Delivery period shall be as per terms and
conditions of Purchase order and any delay in drawing
approval will not be considered as reason for delay in
delivery.
.
22.1.3. As-built drawings
Vendor’s site representative shall mark-up all the engineering
modifications done at site on one master copy at site. The mark-ups
shall be transferred to Client’s copy periodically. THREE master
copies to be maintained by him at site.
The changes made at site in the master copy shall be
incorporated in “As-built” documentation to be submitted by the
vendor as per requirements given above.
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SPECIFICATIONS FOR
DCS
Page 81 of 124
COMPLIANCE DECLARATION & PTR
Please note that vendor shall indicate his replies to the following points without
which the offer shall be liable for rejection.
Deviations, if any, from INDORAMA ICS specifications, shall be listed in the
enclosed format (List of Deviations) indicating the applicable specification
clause. The vendor will be made liable for full compliance with the specification
requirements, if deviations are not listed in ‘List of Deviations’, as it will be
deemed as ‘No deviation’.
SR.
NO.
DESCRIPTION
EXPECTED
REPLY
1. Confirm that all deviations against INDORAMA
ICS specifications are consolidated under “List
of Deviations”.
Deviations mentioned
elsewhere will not be taken into
consideration.
2. Confirm that a soft copy of the technical bid,
as per the attached format, is submitted with
the technical offer.
3. Confirm that there is no discrepancy in the
technical details outlined in the hard and soft
copy of the offer.
4. Relevant Catalogues / literature giving
specifications for all models offered including
sizing data is enclosed with the offer.
5. Relevant Catalogues/specifications of all
bought out items is enclosed with the offer.
No Deviation
6. Quoted for Spare parts recommended for 2
years continuous trouble-free operation along
with listing.
7. Quoted
and
offered
recommended
Commissioning spares along with listing.
Quoted
8. Quoted for ‘Mandatory spares’ if specified in
INDORAMA ICS specifications along with
listing.
Quoted
CONFIRMATION
BY VENDOR
REMARKS
Yes
No
Discrepancy
Yes
Yes
Quoted
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DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
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WEST AFRICA
9. Confirm that PTR form, as per attached
format, is submitted with the technical offer
in any of the following cases:
a)
Vendor has not supplied the item to
INDORAMA ICS.
b)
Items/ part items not supplied to
INDORAMA ICS.
c)
INDORAMA ICS Enquiry specifically
asks for PTR.
(Signature of Vendor)
Name:
Designation:
Date:
SPECIFICATIONS FOR
DCS
Page 82 of 124
Yes
(Company Seal)
LIST OF DEVIATIONS
Doc. No:
Sr.
Clause No.
Subject /
Description
Deviation
Page No.
No.
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DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
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WEST AFRICA
(Signature of Vendor)
Name:
Designation :
Date
:
SPECIFICATIONS FOR
DCS
Page 83 of 124
(Company Seal) PROVEN TRACK
RECORD
I)
Vendor to submit the filled PTR form as part of the initial offer itself in the
following cases:
(a) Vendor has not supplied the item to INDORAMA ICS
(b) The vendor offer contains items / part items not supplied by vendor to
ICS INDORAMA. e.g. accessory like Solenoid valve, limit switch, I/O
card, control valve body etc.
(c) PTR form is specifically required as per the INDORAMA ICS enquiry
specification.
II)
PTR form, when required to be filled in, shall be submitted by vendor as part
of the initial offer failing which their offer shall not be processed further.
III)
Vendor to fill the respective clause in the 'Compliance Declaration' form
correctly.
IV)
Vendor to submit the PTR details in the format given below. All entries shall
be for items which have been commissioned for more than a year. Vendors
are required to fill out the contact details of the person (from End customer)
from whom feedback regarding operation of item can be taken.
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SPECIFICATIONS FOR
DCS
Page 84 of 124
PTR FORM
Sr.
No.
Product /
Accessory
End
Customer
Country
Plant /
Project
name
Date of
Supply
Date of
Comm.
End customer contact details
Name
Tel.
No.
Mobile
No.
E-mail id
1
2
3
4
5
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SPECIFICATIONS FOR
DCS
Page 85 of 124
ANNEXURE-I
INPUT / OUTPUT REQUIREMENTS
REDUNDANT
INPUTS
OUTPUTS
86
30
10
8
30
16
10
45
66
6
25
10
20
30
10
8
30
16
10
45
75
6
25
10
30
30
20
70
40
20
10
330
480
16
220
190
144
150
192
246
122
102
768
1056
48
TAS
COMMON
54
0
108
0
0
0
0
610
WB
238
20
0
WOB
DO-MCC (THROUGH RELAY
22
TAP
WOB
AO 4-20 mA HART
WI
DI-MCC (THROUGH RELAY)
WOB
DI-SWITCH (THROUGH
RELAY)
280
WB
220
20
WI
WOB
DI -SWITCH/PROXI.
THERMOCOUPLE
RTD
AI (4-20 mA HART)
WOB
AI (4-20 mA) MCC
WI
55
WI
50
35
WOB
DO
AO(4-20 mA HART)
DI
105
50
0
THERMOCOUPLE
74
SAP-1
TOTAL
INCLUDING
(20%
spare)
CONTACT
50
WI
WOB
WB
UNIT
RTD
AI 4-20 mA HART
CONTACT
SOV/OTHERS (THROUGH
WETTED RELAY
OUTPUTS
WOB
INPUTS
NON REDUNDANT
355
ABBREVIATIONS:
WB: WITH SAFETY BARRIERS
WOB: WITHOUT SAFETY BARRIERS
WI:
WITH ISOLATOR
The I/O count given above does not include the digital / analog inputs
used to generate hardware alarms like fan failure, high cabinet
temperature, bulk power supply failure, etc. For such alarms vendor
should estimate separate dedicated hardware for implementation.
These shall not be consumed from the available spares.
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SPECIFICATIONS FOR
DCS
Page 86 of 124
SERIAL LINK/ SUB SYSTEM REQUIREMENTS
Sr.
No.
Unit
System
Location
Description
Type of
serial link
Single/
RS485 ,
Modbus
RTU/ Mod
bus TCP
Single/
RS485 ,
Modbus
RTU/Modbus
TCP
1
Serial
links
Maximum no.
dedicate
of tag
d (D)/ or
information
through
flow
controller
(C)
50 Meter Dedicated 50
1
50 Meter Dedicated 50
Single/
RS485 ,
Modbus
RTU/Modbus
TCP
Single/
RS485 ,
Modbus
RTU/Modbus
TCP
Single/
RS485 ,
Modbus
RTU/Modbus
TCP
Single/
RS485 ,
Modbus
RTU/Modbus
TCP
1
50 Meter Dedicated 50
1
50 Meter Dedicated 50
1
50 Meter Dedicated 50
2
50 Meter Dedicated 50
1
SAP-1 TURBO
BLOWER VOITH
GOVERNER
SAP-1
CABINET
ROOM
2
SAP-1 TURBO
BLOWER
VIBRATION
MONITRING
SYSTEM
SAP-1
CABINET
ROOM
3
ACID COOLER
ANODIC
PROTECTION
SAP-1
CABINET
ROOM
4
TAP WOODWARD TAP
GOVERNER
CABINET
ROOM
5
TAP VIBRATION
MONITORING
SYSTEM
TAP
CABINET
ROOM
6
TAP ELECTRICAL
TAP
PROTECTION
RELAY/EXICTATION
CONTROLLER
CABINET
ROOM
Distance
No. of from Rack
serial
Room
links
( Note 2)
per
system
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
7
5
6
6
7
TAS WOODWARD TAS
GOVERNER
CABINET
ROOM
Single/
RS485 ,
Modbus
RTU/Modbus
TCP
TAS VIBRATION
TAS
CABINET
Single/
ROOM
MONITORING
RS485 ,
SYSTEM
Modbus
RTU/Modbus
TCP
TAS ELECTRICAL
TAS
CABINET
Single/
ROOM
PROTECTION
RS485 ,
RELAY/EXICTATION
Modbus
CONTROLLER
RTU/Modbus
TCP
AIR COMPRESSORS COMMON FIELD
Single/
RS485 ,
Modbus
RTU/Modbus
TCP
ELECTRICAL
COMMON MCC/CABINET Single/
ROOM
PROTECTION
RS485 ,
RELAY,
Modbus
NUMERICAL
RTU/Modbus
RELAYS
TCP
SPECIFICATIONS FOR
DCS
1
50 Meter Dedicated 50
1
50 Meter Dedicated 50
2
50 Meter Dedicated 50
4
300 Meter Dedicated 50
6
150 Meter Dedicated 50
Page 87 of 124
NOTES:
1) The I/O count given above does not include the digital / analog inputs used to
generate hardware alarms like fan failure, high cabinet temperature, bulk power
supply failure, FF physical layer diagnostic alarms, etc. For such alarms vendor
should estimate separate dedicated hardware for implementation. These shall not
be consumed from the available spares.
2) Modbus Cable shall be 2 Pair Twisted Individual & Overall Screen Armoured Cable,
18AWG copper conductor, armoured, with overall screen, PVC insulation, PVC sheath to
be included by vendor. The exact cable length shall be decided during detail engineering.
3) Applicable standard for MODBUS cable : EN50288, IEC60331, IEC60332
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
SPECIFICATIONS FOR
DCS
Page 88 of 124
ANNEXURE-III
SR. NO.
I/O LIST AND BOM QUOTED BY DIFFERENT VENDORS
A
I/O SUMMARY
CR-1
Description
1
2
3
4
5
6
7
8
Quantity
Model No.
Quantity Reqd.
Comments
Model No.
Quantity Reqd.
Comments
Model No.
Quantity Reqd.
Comments
Quantity
Model No.
Quantity
Comments
Model No.
Quantity Reqd.
Comments
Model No.
Quantity
Comments
Quantity
Model No.
Quantity
Comments
Model No.
Quantity Reqd.
Comments
Model No.
Quantity
Comments
4~20mA anlaog
inputs
(nonredundant) with
and
without
barriers
Pulse inputs
(non-redundant)
with and without
barriers
Digital inputs
(redundant)
proximity +
contact Digital
inputs (nonredundant)
proximity +
contact
Digital outputs
(redundant) for
SOV & Others
Digital outputs
(non-redundant)
for SOV &
Others
10
FF inputs +
outputs
B
I/O SUMMARY
CR-2
Description
4~20 mA analog
inputs
(redundant) with
and
without
barriers
4~20 mA
outputs
(redundant) with
and without
barriers
3
4~20mA anlaog
inputs (nonredundant) for
open loops with
and without
barriers Digital
inputs
(redundant)
proximity +
contact
4
Digital inputs
(nonredundant)
proximity +
contact
5
Digital outputs
(redundant)
6
Digital outputs
(non-redundant)
C
I/O SUMMARY
CR-3
Description
1
VENDOR 3
Pulse inputs
(non-redundant)
RS-485 Modbus
Inputs
2
VENDOR 2
4~20 mA analog
inputs
(redundant) with
and
without
barriers
4~20 mA analog
outputs
(redundant) with
and
without
barriers
9
1
VENDOR 1
4~20 mA analog
inputs
(redundant) for
closed
loops
with
and
without
barriers
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
2
3
Others
5
FF inputs +
outputs
OTHER HARDWARE REQUIRED
1
FTA/Terminal Board for 4~20mA
analog inputs (redundant)
2
FTA/Terminal Board for 4~20mA
analog inputs(non-redundant)
3
FTA/Terminal Board for 4~20mA
analog outputs (redundant)
4
FTA/Terminal Board for digital inputs
(redundant)
5
FTA/Terminal Board for digital inputs
(non-redundant)
6
FTA/Terminal Board for digital outputs
(redundant)
7
FTA/Terminal Board for digital outputs
(non-redundant)
8
Special high capacity relays to drive
DC loads of HT switchgear
9
HART Multiplexer Slaves 16 points
10
Hart Multiplexer Masters 16 points
HART Patch Cards 16 points
11
Redundant Power Supplies for I/O
modules including installed spares
12
13
14
15
Page 89 of 124
4~20 mA analog
outputs
(redundant) for
closed loops
with and
without
barriers
4~20mA anlaog
inputs (nonredundant) for
open loops with
and without
barriers Digital
inputs (nonredundant)
proximity +
contact
Digital outputs
(nonredundant) for
SOV &
4
D
SPECIFICATIONS FOR
DCS
Model No.
Quantity
CR1/CR2/CR3
Comments
Model No.
Quantity
CR1/CR2/CR3
Comments
Model No.
Quantity
CR1/CR2/CR3
Comments
Model No.
Quantity
CR1/CR2/CR3
Comments
Model No.
Quantity
CR1/CR2/CR3
Comments
Model No.
Quantity
CR1/CR2/CR3
Comments
Redundant FF Power Supplies 500
mA with advanced diagnostic
modules
Segment protectors 12 way, mounted
in FRP/Polycarbonate junction boxes
with surge arresters, terminators, and
terminals for trunk and spur cables
Surge arresters in control room, one
per segment.
OS consisting of dual 22" TFT screen,
Membrane Keyboard,Optical Mouse,
PC,etc.
Engineering station / server consisting
of single 24” led screen, Qwerty
Keyboard,
16
Optical Mouse, Server
17
Network Laser Printer A3/A4 size B/W
18
Colour Laser Network Printer A3/A4
19
Serial Gateway * port for third party
devices
20
Ethernet Switch
21
Redundant Controller with redundant
I/O communication and redundant
Ethernet communication
22
Firewall
23
HART maintenance PC workstation
with 22" TFT screen, Qwerty
Keyboard, Optical
24
Mouse,
25
I/O racks
26
FO Cable with patch cards, LIU and
other hardware for redundant RIO link
and data highway extension to CEU
control room.
27
External Firewall to interface to
client's LAN.
28
E
BOUGHT OUT ITEMS
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
1
Barriers + isolators for analog inputs
single channel
2
Barriers + isolators for analog outputs
single channel
3
Barriers for digital/proximity inputs
4
Trip amplifiers (HART pass through)
5
Off-delay timers ǔP Digital indicators
ǔP One Loop Controllers
6
Panel to house the above
indicators/controllers ǔP Alarm
Annunciator 16 windows along with
hooter and test/reset/acknowledge
Push buttons
7
Illuminated push buttons
8
Two position selectord switches Key
switches
9
Indicating lamps
10
Console to mount the above push
buttons/lamps /switches
11
MCBs double pole of different ratings
(for TKIS-India use only)
12
MCCBs to isolate incoming power
supply from UPS
13
Voltmeter/ammeter/CTs for ammeter
etc.for incoming power supply. Signal
distributor (1 input, 2 outputs) for
analog inputs
14
Single channel isolation amplifier 1
input 2 outputs for proximity inputs
DIN rail mounted relays 2NO+2NC
SPECIFICATIONS FOR
DCS
Page 90 of 124
15
16
17
18
19
20
21
F
CONTROL ROOM FURNITURE
1
Operator console
2
Engineering stn/server + printer table
3
Chairs
4
Printers tables
5
Corner consoles
G
LICENSED SOFTWARE
1
MS WINDOWS FOR OS,ES/Servers,
HMS
2
Portable CD/DVD read / write driver
software OS run time software
2
MS office software
3
ES software consisting of tag
database generation, graphics, loop
and logics, sequences, trends, self
tuning, alarms & events, diagnostics,
etc.
4
Server software if required; including
redundancy software, and other
special software if any.
5
HMS software for unlimited tags
6
OPC server DA software for unlimited
tags
7
Controller software including
redundancy
8
Controller firewall software
9
Special documentation software to
enable printouts of logics, loops, tag
database, etc. from ES / exporting the
same to MS Office.
10
Log reports software for OS Modbus
driver software
Quantity
CR1/CR2/CR3
Comments
Quantity
CR1/CR2/CR3
Comments
Quantity
CR1/CR2/CR3
Comments
Quantity
CR1/CR2/CR3
Comments
Quantity
CR1/CR2/CR3
Comments
Quantity
CR1/CR2/CR3
Comments
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
11
Extetnal Firewall software
12
Third party diagnostic software for FF
physical layer diagnostics
SPECIFICATIONS FOR
DCS
Page 91 of 124
13
14
H
CONSUMABLES
1
Colour printer cartridge for printer
2
B&W printer cartridge for B&W
printers
3
A4 size sheets for printer
4
A3 size paper for A3/A4 printer
5
Fuses
Quantity
CR1/CR2/CR3
Comments
Quantity
CR1/CR2/CR3
Comments
Quantity
CR1/CR2/CR3
Comments
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
SPECIFICATIONS FOR
DCS
Page 92 of 124
ANNEXURE-III
APPLICABLE HARDWARE UNIT RATES FOR ADDITION / DELETION
Sr. No.
Description
UOM
Qty.
1
Analog input
module
(redundant) with
all accessories like
terminal board,
pre-fab cable etc.
for closed & open
loops
nos.
1
2
Analog output
module
(redundant) with
all accessories like
terminal board,
pre-fab cable etc.
for closed & open
loops loops
nos.
1
3
Analog input
module (nonredundant) with
all accessories like
terminal board,
pre-fab cable etc.
for open loops
nos.
1
4
Analog output
module (nonredundant) with
all accessories like
terminal board,
pre-fab cable etc.
for open loops
nos.
1
5
Digital input
module
(redundant) with
all accessories like
terminal board,
pre-fab cable etc
nos.
1
6
Digital input
module (nonredundant) with
all accessories like
terminal board,
pre-fab cable etc.
nos.
1
7
Digital output
module
(redundant) with
all accessories like
terminal board,
pre-fab cable etc.
nos.
1
8
Digital output
module (nonredundant) with
all accessories like
terminal board,
pre-fab cable etc.
nos.
1
9
Digital input
module for SOE
10
Pulse input
module with all
accessories like
terminal board,
pre-fab cable etc.
Unit rate (USD)
Total Price
(USD)
Taxes
P&F
Transport
Cost
1
nos.
1
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
11
Serial interface
input module with
all accessories
12
RTD input module
1
13
T/C input module
1
14
Set of redundant
controller CPU
module with
redundant power
supply modules
and redundant
communication
interface with data
highway and I/O
bus along with all
accessories.
nos.
1
15
Relay boards for DI
with 16 relays
nos.
1
16
Relay boards for DI
with 32 relays
nos.
1
17
Relay Boards for
DO with 16 relays
nos.
1
18
Relay boards for
DO with 32 relays
nos.
1
19
AI Barriers
nos.
1
20
AO Barriers
nos.
1
21
DI barriers (for
proximity
switches) single
channel
nos.
1
22
DI barriers (for
proximity
switches) double
channel
nos.
1
23
DI barriers (for
proximity
switches) single
channel 1 input X 2
outputs
nos.
1
24
DO barriers
nos.
1
25
RTD barriers
nos.
1
26
T/C barriers
nos.
1
27
Trip Amplifiers
with two
independently
adjustable alarm
settings
nos.
1
28
Distributors 1 no.
4~20 mA input X 2
nos 4~20 mA
outputs
nos.
1
29
Digital timers
on/off delay delay
setting between
1~500s
nos.
1
30
DIN Rail mounted
relays 2NO/NC
nos.
1
31
SIL approved relay
2 NO/NC
nos.
1
32
Push Buttons
nos.
1
33
Illuminated Push
Buttons
nos.
1
nos.
SPECIFICATIONS FOR
DCS
Page 93 of 124
1
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
34
Two Position
Selector Switches
nos.
1
35
Key Switches
nos.
1
36
Indicating Lamps
nos.
1
37
MCBs
nos
1
38
Redundant FF
power supply
module 500 mA
nos.
---
39
Redundant FF H1
card
nos.
---
40
Advanced
diagnostic module
for FF physical
layer
nos.
1
41
FF Terminators
nos.
---
42
FF segment surge
arresters
nos.
---
43
Segment protector
12 way for FF
spurs mounted in
FRP/polycarbonate
JB complete with
surge protector,
terminator,
terminals, and
other necessary
hardware
nos.
1
44
HART patch card
16 pt
nos.
1
45
HART multiplexer
slave 16 pt
nos.
1
46
HART Multiplexer
master 16 pt
nos.
1
47
Armoured Modbus
Communication
cable
nos.
1
0
48
Armoured FO
cable 4 fibre with
necessary
hardware as below
m
1
0
(a) Patch Card
nos.
1
(b) Patch Panel
nos.
1
(c )FO converter
nos.
1
(d) Terminators
nos.
1
m
1
(a) Patch Card
nos.
1
(b) Patch Panel
nos.
1
(c )FO converter
nos.
1
(d) Terminators
nos.
1
50
Man-day rates
beyond stipulated
minimum period
nos
1
0
51
Marshalling
Cabinet
nos
1
0
49
Armoured FO
cable 6 fibre with
necessary
hardware as below
SPECIFICATIONS FOR
DCS
Page 94 of 124
0
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
52
System cabinet
nos
1
0
53
Power distribution
board
nos
1
0
54
Power module
nos
1
0
(a)Power supply
unit 10A
nos
1
0
(b)Power supply
unit 20A
nos
1
0
(c)Power supply
unit 40A
nos
1
0
55
Ethernet switch
*****port
nos
1
0
56
I/O Point
addition/deletion
services beyond
5% of wired I/Os
nos
1
0
TOTAL
SPECIFICATIONS FOR
DCS
Page 95 of 124
0
Final cost including taxes, packing forwarding and transport
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
SPECIFICATIONS FOR
DCS
Page 96 of 124
ANNEXURE-IV
BIDDER to fill in the complete form for technical comparison purpose.
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
SPECIFICATIONS FOR
DCS
SOFTWARE WISE
OSI,
PLATFORM
INDEPENDENT
BOUGHT OUT ITEM
AVAILABLE IN OPEN
MARKET, LIKE SERVER
, MEMORY, PRINTERS,
ETC..
AVAILABLE IN OPEN MARKET
YES
REAL
TIME
SYSTEM
TRANSPARENT TO OUT SIDE
NETWORK
Page 97 of 124
DATA YES,
THRU
TCP/IP
OVER
ETHERNET
HARDWARE FOR
PLANT MIS (LAN)
USER WRITTEN "C++" OR ANY OTHER YES,
SUPPORT
HIGH LEVEL LANGUAGE
REQUIRED FOR C, C++
PROGRAM FOR ANY APPLICATION
OR VB APPLICATION
APART
FROM
CONTROL
PROCESSOR’S
STANDARD
ALGORITHEMS
SUPPORT FOR ANY 3RD PARTY YES
SOFTWARE RUNNING IN THE SYSTEM
MAIN FILE SERVER OR
WORK STATION
COMM. WITH ANY OTHER 3RD PARTY YES (DDE/OPC/ODBC,
PACKAGES LIKE MICROSOFT OR
ETC.)
ORACLE
TAG
DATA
AVAILABILITY
OPERATING SYSTEM PROMPT
AT YES
APPLICATION PROGRAM INTERFACE YES, THROUGH USER
SOFTWARE FOR REAL TIME DATA
WRITTEN PROGRAM
MANIPULATION
12
MAIN SYSTEM HARDWARE
13
MAIN SYSTEM SOFTWARE (O.S.)
LATEST
14
RDBMS
ORACLE/SQL SERVER
WITH
LATEST
SOFTWARE
VERSION
AT THE TIME OF
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
SPECIFICATIONS FOR
DCS
Page 98 of 124
SUPPLY
15
IF OPERATING SYSTEM IS WINDOWS YES, BIDDER TO GIVE
NT, VIRUS PROTECTION FOR THE
ALL DETAILS
ENITRE SYSTEM
16
SOFTWARE / FIRM WARE UPGRADE YES
FOR THE NEXT FIVE YEARS AT FREE
OF COST
17
SYSTEM HARDWARE , SOFTWARE
AND ALL BOUGHT OUT ITEMS ,
INCLUDING ANY FIRMWARES ARE
HAVING PROVEN TRACK RECORD
FOR INDIAN OR ABROAD MARKET
18
SYSTEM CONFIGURATION
CAN BE DONE ON LINE OR OFF LINE
YES,
VENDOR
TO
PROVIDE PTR DETAILS
WITH
RUNNING
INSTALLATION
YES, BOTH
SYSTEM
CONFIGURATION BOTH, THERE SHALL
DEVELOPMENT TOOL IN SYSTEM /
BE
MIN.
TWO
P.C.
ENGINEERING
STATION,
INDEPENDENT OF EACH
OTHER, FROM
WHERE
COMPLETE
PLANT DATABASE/
SYSTEM
CONFIGURATION/GRAP
HIC GENERATION ETC.
CAN BE DEVELOPED/
DEPLOYED
MAX. TAGS SUPPORTED BY THE
SYSTEM
MIN. 10,000
ON LINE CONTEXT SENSITIVE HELP
YES, AT EACH LEVEL
ADDITION OR DELETION OF ANY I/O YES
MODULE IN RUN TIME
ADDITION OR DELETION OF ANY BONUS
CONTROL STATION IN RUN TIME
ADDITION /DELETION OF ANY SINGLE YES
OPEN AND CLOSE LOOP IN RUN TIME
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
BUILDING A NEW GRAPHIC
MODIFICATION IN RUN TIME
MODIFICATION
OF
STRATEGY IN RUN TIME
SPECIFICATIONS FOR
DCS
Page 99 of 124
OR YES
CONTROL YES
CHANGE OF ANY TAG NAME IN RUN
TIME
YES
CHANGE
OF
ANY
SOFTWARE YES
CONNECTION IN CONTROLLER IN
RUN TIME
19
SECURITY
WITH DIFF. LEVEL OF
PASSWORD FOR DIFF.
CATEGORY
OF
OPERATION
MAIN FILE SERVER ( ENGINEERING
TOTAL QTY.-2
STATION)
PROCESSOR
LATEST
GRADE
PROCESSOR
SERVER
RAM
32 GB MIN.
SSD
1TB GB MIN. , RAID-I,
HOTSWAPPABLE FOR
ALL THE STATIONS,
WHERE PROJECT,
SYSTEM
CONFIGURAITON
DATABASE AS WELL AS
HISTORICAL
TREND,
LOGS, ETC. RESIDES.
THIS MAY INCLUDE
OPERATOR STATIONS
ALSO, DEPENDING
SYSTEM
ARCHITECTURE
PORTABLE USB SSD
YES
DVD WRITER
YES
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
SPECIFICATIONS FOR
DCS
DISPLAY
24” wide screen LED type
colour monitor only,
1
NO. WITH
EACH
ENGINEERING
STATION. MIN. DISPLAY
RESOLUTION 1024X768
REDUNDANCY OFFERED FOR SSD
1 TB MIN. , RAID-I,
HOTSWAPPABLE FOR
ALL THE STATIONS,
WHERE PROJECT,
SYSTEM
CONFIGURAITON
DATABASE AS WELL AS
HISTORICAL
TREND,
LOGS, ETC. RESIDES.
THIS MAY INCLUDE
OPERATOR STATIONS
ALSO,
DEPENDING
SYSTEM
ARCHITECTURE
SERIAL / PARALLEL PORTS
MIN. 2 EACH TYPE
DOT MATRIX PRINTERS
NOT REQUIRED
INKJET PRINTERS
MIN. 1 A3 SIZE WITH
EACH
ENGINEERING
STATION,
LOCALLY
ACCESSIBLE
FROM
THAT
PARTICULAR
ENGGINEERING
STATION.
(TOTAL =2
FOR
2
NOS.
OF
ENGINEERING
STATION)
DISK USAGE LIMIT
YES
,
FEATURE
Page 100 of
124
SYSTEM
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
20
SPECIFICATIONS FOR
DCS
SECURITY
WITH DIFF. LEVEL OF
PASSWORD FOR DIFF.
CATEGORY
OF
OPERATION
FILE , DIRECTORY LEVEL SECURITY
YES
ETHERNET PORT FOR MIS /
XWINDOWS
YES , 1 MIN ON EACH
MACHINE
IN
THE
COMPLETE SYSTEM
Page 101 of
124
WORKSTATION
PROCESSOR MAKE / MODEL / SPEED LATEST
GRADE
PROCESSOR
SEREVR
AVAILABLE RAM
32 GB MIN.
HDD
1 TB MIN. , RAID-I,
HOTSWAPPABLE FOR
ALL THE STATIONS,
WHERE PROJECT,
SYSTEM
CONFIGURAITON
DATABASE AS WELL AS
HISTORICAL
TREND,
LOGS, ETC. RESIDES.
THIS MAY INCLUDE
OPERATOR STATIONS
ALSO, DEPENDING
SYSTEM
ARCHITECTURE
DVD WRITER
YES
SERIAL / PARALLEL PORTS
MIN. 2 PORTS OF EACH
TYPE
DOT MATRIX PRINTERS
132 COLUMN, MIN. 2 ,
ONE FOR LOG AND ONE
FOR ALARM , BOTH
SHOULD HAVE
GLOBAL
ACCESSIBILITY
VIA
ETHERNET NETWORK
PRINTER PORT.
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
SPECIFICATIONS FOR
DCS
INKJET PRINTERS
MINIMUM 1 NO. OF A3
IZE INKJET PRINTER
WITH
ETHERNET
INTERFACE, WHICH IS
GLOBALLY
ACCESSIBLE FROM ALL
OPERATOR STATIONS
ON NETWORK FOR
COLOUR
GRAPHIC/TREND
PRINTING.
(GRAND
TOTAL=
3
NOS. OF PRINTERS)
DISK USAGE LIMIT
YES
,
FEATURE
ETHERNET PORT FOR MIS /
XWINDOWS
YES, MIN. ONE NO.
DISPLAY SIZE
24” WIDE SCREEN
LED TYPE COLOUR
MONITOR
DISPLAY RESOLUTION
MIN. 1024x768
MOUSE
AND
KEY
CONCURRENT OPERATION
Page 102 of
124
SYSTEM
BOARD YES
QWERTY TYPE ENGINEERING KEY
BOARD
YES , 1 NO.
MEMBRANE TYPE OPERATION KEY
BOARD
YES, 1 NO.
TOUCH SCREEN
YES
MIN. DISPLAY CALL UP TIME FOR MAX. MAX. 2 SEC.
LOADED GRAPHIC
DISPLAY REFRESH RATE
MAX. 2 SEC.
LIMIT ON NOS. OF DYNAMIC POINT IN NO LIMIT
A SINGLE GRAPHIC
GLOBAL CONTROLS OF ANY PLANT YES
AREA FROM ANY WORKSTATION
GRAPHICS
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
SPECIFICATIONS FOR
DCS
Page 103 of
124
MASKING, ACCESS LIMIT OF ANY YES
GRAPHICS OR PART THEREOF BY
PASSWORD
COMMON STATION FOR OPERATION YES
AND ENGINEERING
ANY OTHER FEATURES
*
LIMITATIONS
NO LIMITATIONS
21
TYPE OF PRINTER SUPPORTED
RS232C/USB
SERIAL
AND CENTRONICS
PARALLEL / ETHERNET
NETWORK PRINTERS
22
INK JET PRINTERS
A3 SIZE INKJET ,
SERIAL
INTERFACERS323C/US
B PRINTER , MIN. 300
DPI RESOLUTION,
AVAILABLE IN
OPEN MARKET
MIN. 1 NO. WITH EACH
ENGINEERING
STATION
(TOTAL
2
ENGG. STATION) AND
MIN. 1 NO. OF A3 SIZE
INKJET PRINTER WITH
ETHERNT
NETWORK
PORT FOR ALL
OPERATOR STATIONS,
GLOBALLY
ACCESSIBLE
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
23
NOS. OF PRINTERS SUPPORTED
SPECIFICATIONS FOR
DCS
Page 104 of
124
MIN. 3 NOS. 1 NO OF
ALARM PRINTER( 132
COLUMN DOT MATRIX,
ETHERNET PORT), 1
NOS. OF LOG PRINTER
(132
COLUMN,
ETHERNET PORT) AND
1
NO.
OF
VIDEO
COPIER(A3
INKEJT
WITH ETHERNET
PORT)
ADDITIONALLY THERE
SHALL BE A3 SIZE
INKJET
PRINTER
ALONG WITH EACH
ENGINEERING
STATION AS SPECIFIED
ABOVE.
24
VIDEO
COPIER
GLOBAL ACCESS
25
CONTROL STATION
AND
PRINTER YES,
MUST
VIA
ETHERNET PORT AS A
NETWORK PRITNER
TYPE OF PROCESSOR / SPEED
64
BIT
MINIMUM
PROCESSOR
USER RAM
MIN. 32 MB
MIN. CYCLE
SCANNING
TIME
FOR
INPUT 50 M SEC
MIN. CYCLE TIME FOR ALGORITHM
EXECUTION
250 MSEC OR BETTER
MIN. CYCLE TIME FOR OUTPUT
WRITING
50 MSEC
NORMAL SOFTWARE LOADING
30%
SOFTWARE LOADING IN WORST
CONDITION
40%
FUTURE MARGIN
SOFTWARE LOAD
AVAILABLE
IN 50%
All rights reserved
SPECIFICATIONS FOR
DCS
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
REDUNDANCY OFFERED
26
Page 105 of
124
YES , FULL, FAULT
TOLERANT, HOT
SWAPPABLE
DIGITAL INPUT CARD
NO. OF CHANNEL
MAX. 16
CARD
NOS. PER
INTERROGATION VOLTAGE
24 V DC
CHANNEL STATUS LED
YES , PER CHANNEL
CHANNEL ISOLATION ( CHANNEL TO YES,
>1000V
DC
CHANNEL AND CHANNEL TO FIELD, OPTICALLY ISOLATED
ALL CHANNEL SHALL HAVE
AS PER IEC:XXX
INDIVIDUAL ISOLATION, NO GROUP
ISOLATED CARDS ARE ACCEPTED)
27
EARTH FAULT DETECTION CKT.
YES, WITH ALARMS
OVER CURRENT PROTECTION BY
YES , WITH ALARMS
LOOP CURRENT
MAX. 2 AMP.
SURGE WITH STAND CAPACITY
YES , AS PER IEC:XXX
SCAN RATE
50 MILLI SECOND OR
BETTER
REDUNDANCY
NO
Testable
YES
DIGITAL OUTPUT CARD
NO. OF CHANNEL
MA.X 16 PER CARD
DRIVING VOLTAGE
24 V D.C.
CHANNEL STATUS LED
YES, PER CHANNEL
CHANNEL ISOLATION ( CHANNEL TO OPTICALLY ISOLATED
CHANNEL AND CHANNEL TO FIELD,
ALL CHANNEL SHALL HAVE
INDIVIDUAL ISOLATION, NO GROUP
ISOLATED CARDS ARE ACCEPTED)
EARTH FAULT DETECTION CKT.
YES, WITH ALARMS
OVER CURRENT PROTECTION BY
YES, WITH ALARMS
MAX LOOP CURRENT
2 AMP.
SURGE WITH STAND CAPACITY
YES, AS PER IEC:XXX
SCAN RATE
50 MILLI
BETTER
SEC
OR
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
28
SHORT CIRCUIT PROTECTION
YES, WITH ALARMS
PROTECTION AGAINST BACK EMF.
YES, AS PER IEC:XXX
REDUNDANCY
NO
Testable
YES
SPECIFICATIONS FOR
DCS
Page 106 of
124
ANALOG INPUT CARD
NO. OF CHANNEL
MAX. 16 PER CARD
TYPE OF INPUT
SHALL BE CAPABLE OF
ACCEPTING 4-20 MA
INPUT FROM 2 WIRE
AND
4
WIRE
TRANSMITTERS, ALSO
POWER UP 24 V DC
TWO
WIRE
TRANSMITTER. SHALL
HAVE MIN. 250 OHM
RESISTOR, SO THAT
HART COMMUNICATOR
CAN BE PLACED IN
PARALLEL
WITHOUT
DISCONNECTING THE
TRANSMITTER LOOP
AT ANY TIME
DRIVING VOLTAGE
24 V D.C.
CHANNEL STATUS LED
YES
CHANNEL ISOLATION ( CHANNEL TO YES, GALVANICALLY
CHANNEL AND CHANNEL TO FIELD, ISOLATED
ALL CHANNEL SHALL HAVE
INDIVIDUAL ISOLATION, NO GROUP
ISOLATED CARDS ARE ACCEPTED)
EARTH FAULT DETECTION CKT.
YES,WITH ALARMS
OVER CURRENT PROTECTION BY
YES,WITH ALARMS
MAX LOOP CURRENT
100 mAMP
SURGE WITH STAND CAPACITY
YES, AS PER IEC:XXX
SHORT CIRCUIT PROTECTION
YES, WITH ALARMS
TYPE OF ADC /RESOLUTION
MIN. 13 BIT
ACCURACY
+/- 0.075%
SCAN RATE
250 M SEC OR BETTER
REDUNDANCY
AS PER REQUIRMENT
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
Testable
SPECIFICATIONS FOR
DCS
Page 107 of
124
YES
28.1 ANALOG OUTPUT CARD
NO. OF CHANNEL
MAX. 8 PER CARD
OUTPUT
4-20 MA DC OUTPUT,
ISOLATED IN MAX. 750
OHM
CHANNEL STATUS LED
YES
CHANNEL ISOLATION ( CHANNEL TO YES, GALVANICALLY
CHANNEL AND CHANNEL TO FIELD, ISOLATED
ALL CHANNEL SHALL HAVE
INDIVIDUAL ISOLATION, NO GROUP
ISOLATED CARDS ARE ACCEPTED)
29
EARTH FAULT DETECTION CKT.
YES,WITH ALARMS
OVER CURRENT PROTECTION BY
YES,WITH ALARMS
MAX LOOP CURRENT
30 mAMP
SURGE WITH STAND CAPACITY
YES, AS PER IEC:XXX
SHORT CIRCUIT PROTECTION
YES, WITH ALARMS
TYPE OF ADC /RESOLUTION
MIN. 10 BIT
ACCURACY
+/- 0.1%
SCAN RATE
1 SEC OR BETTER
REDUNDANCY
NO
Testable
YES
THERMOCOUPLE INPUT CARDS
MAX. NO. OF CHANNEL PER CARD
16 NOS.
TYPE OF INPUT THERMOCOUPLES
E,J,K,R,S,B,T, ETC..
CALIBRATION OF CARD AS PER
AS PER ANSI:MC96.1
CALIB. FREQ.. REQUIRED
MIN.
CHANNEL ISOLATION ( CHANNEL TO YES, MIN 1000 VAC,
CHANNEL AND CHANNEL TO FIELD, GALVANICALY
ALL CHANNEL SHALL HAVE
ISOLATED
INDIVIDUAL ISOLATION, NO GROUP
ISOLATED CARDS ARE ACCEPTED)
ACCURACY
+/- 0.1’C
ADC RESOLUTION
MIN. 13 BIT
MIX. TYPE CONFIGURATION (i.e. DIFF. YES
TYPES OF T/C FOR DIFF. CHANNEL OF
SINGLE CARD)
All rights reserved
SPECIFICATIONS FOR
DCS
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
30
Page 108 of
124
INPUT ISOLATION
GALAVANICALLY
ISOLATED
GROUNDED/UNGROUNDED INPUTS
YES
BURN OUT FEATURE
YES , PER CHANNEL
STATUS LED FOR IND. CHANNEL
YES
SCAN RATE
1 SECOND OR BETTER
REDUNDANCY
NO
RTD INPUT CARDS
MAX. NO. OF CHANNEL PER CARD
16 NOS.
TYPE OF INPUT RTD SENSORS
PT100 , 3 WIRE AND 4
WIRE AND OTHERS
CALIBRATION OF CARD AS PER
AS
DIN:43760/IEC529
CALIB. FREQ.. REQUIRED
MIN.
PER
CHANNEL ISOLATION ( CHANNEL TO YES, MIN. 1000 V AC
CHANNEL AND CHANNEL TO FIELD,
ALL CHANNEL SHALL HAVE
INDIVIDUAL ISOLATION, NO GROUP
ISOLATED CARDS ARE ACCEPTED)
ACCURACY
+/- 0.1 ‘C
ADC RESOLUTION
MIN. 13 BIT
MIX. TYPE CONFIGURATION (i.e. DIFF. YES
TYPES OF RTD FOR DIFF. CHANNEL
OF SINGLE CARD)
31
INPUT ISOLATION
GALVANICALLY
ISOLATED
3 WIRE AND 4 WIRE RTD INPUTS
YES
SHORT CIRCUIT PROTECTION
YES , WITH ALARMS
OPEN CIRCUIT PROTECTION
YES, WITH ALARMS
STATUS LED FOR IND. CHANNEL
YES, WITH ALARMS
EARTH FAULT DETECTION CKT.
YES, WITH ALARMS
OVER CURRENT PROTECTION
YES, WITH ALARMS
SCAN RATE
1 SECOND OR BETTER
REDUNDANCY
NO
CONTROLLER SYSTEM
All rights reserved
SPECIFICATIONS FOR
DCS
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
CONTROLLER CAPACITY
(An array of small controllers clubbed
together to meet this specification will not
be acceptable)
Page 109 of
124
MIN.
100
CLOSED
LOOPS AT 250 MILLI
SECONDS, TOTAL I/O
COUNTS SUPPORTED
BY SINGLE CONTROL
PROCESSOR SHALL BE
MIN.
1000
NOS.CONTROLLER
SHOULD BE CAPABLE
OF
MINIMUM
EXECUTION TIME OF 50
MILLI SECONDS.
CONTROL ALGORITHMS RUNNING IN MAIN
CONTROL
PROCESSOR
AUTO TUNE AS STANDARD FEATURE YES , FOR ALL LOOPS
BY DEFAULT
MAX. ALGORITHM EXECUTION TIME
250 MSEC
MIN. INPUT AND OUTPUT POLL TIME
50
SECOND
BETTER
MAX.
LOAD
APPLICATION
FUTURE
LOAD
MARGIN
FOR
PRESENT 30%
IN
SOFTWARE 50%
OR
CONTROL PROCESSOR IS CAPABLE YES , FOR ALL LOOPS
OF RUNNING THIRD PARTY
PACKAGE
SUPPORT
FOR
ALGORITHMS
ALL
STD. YES , FOR ALL STD.
TYPES AS SPECIFIED IN
ENQ. SPECS ,
INCLUDING
SEQUENTILA,BATCH
AND
CONTINUOS
CONTROL AND MATHS,
LOGIC FUNCITON
ON LINE MODIFICATION /ADDITION
AND DELETION OF ANY LOOP OR
LOOP TAG
YES
PEER TO PEER COMMUNICATION /
LIMITATIONS
YES WITHOUT
TAG LIMIT
ANY
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
PEER TO PEER COMMUNICATION
LOAD
SPECIFICATIONS FOR
DCS
Page 110 of
124
MIN.
SOFTWARE
PARAMETER NO
INTERCONNECTION LIMIT
DATA RETENTION TIME IN RAM
MIN. 1000 HRS.
SELF BOOTABLE
YES
CHECKPOINT FACILITY WITH AUTO
SCHEDULING
YES , AT REGULAR
USER CONFIGURED
INTERVAL
CONTROL
FACILITIES
CONFIGURATION GUI
BASED
,
SUPPORTED
BY
MOUSE
AND
KEY
BOARD
WITH
ALL
TYPES OF EDITING
FEATURES AND ON
LINE CONTEXT
SENSITIVE HELP
AUTOMATIC UPLOAD OF ANY RUN
TIME CHANGES MADE IN CONTROL
YES
DATABASE
32
DOWNLOAD / BOOT TIME
MIN.
SECURITY
WITH DIFF. LEVEL OF
PASSWORD FOR DIFF.
CATEGORY
OF
OPERATION
REDUNDANCY
YES,
100%
REDUNDANT
WITH
FAULT TOLERANT
FEATURES,
HOTSWAPPABLE
REDUNDANCY OFFERED AT
I/O
NO
CPU
YES
(100%
REDUNDANT
WITH
FAULT
TOLERANT
FEATURE WITH HOT
SWAPPABLE
CONFIGURATION)
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
SPECIFICATIONS FOR
DCS
INTERNAL BUSES
YES
(100%
REDUNDANT
WITH
FAULT
TOLERANT
FEATURE WITH HOT
SWAPPABLE
CONFIGURATION)
COMM. MODULE
YES
(100%
REDUNDANT
WITH
FAULT
TOLERANT
FEATURE WITH HOT
SWAPPABLE
CONFIGURATION)
MAIN NODE BUS
YES
(100%
REDUNDANT
WITH
FAULT
TOLERANT
FEATURE WITH HOT
SWAPPABLE
CONFIGURATION)
Page 111 of
124
POWER SUPPLY MODULES OF ALL YES
(100%
SYSTEM CARDS/MODULES/NODES
REDUNDANT
WITH
FAULT
TOLERANT
FEATURE WITH HOT
SWAPPABLE
CONFIGURATION)
CONTROLLERS
YES
REDUNDANT
(100%
WITH
FAULT
TOLERANT
FEATURE WITH HOT
SWAPPABLE
CONFIGURATION)
GATEWAYS
YES
(100%
REDUNDANT
WITH
FAULT
TOLERANT
FEATURE WITH HOT
SWAPPABLE
CONFIGURATION)
WORK STATIONS
YES
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
33
SPECIFICATIONS FOR
DCS
HDD
YES
(100%
REDUNDANT
WITH
FAULT
TOLERANT
FEATURE WITH HOT
SWAPPABLE
CONFIGURATION)
PRINTER BACK UP PORTS
YES,
INCASE
OF
FAILURE OF LOG OR
ALARM PRINTER, THE
OTHER
WORKING
PRINTER SHOULD
AUTOMATICALLY
RESUME THE ROLE OF
THE FAILED PRINTER
Page 112 of
124
COMMUNICATION TO PLC
PROTOCOL
MODBUS-RTU
INTERFACE
2 WIRE RS485
MAX. LENGTH OF INTERFACE CABLE MIN. 1200 MTR.
PERMITTED
NO. OF PORTS ON SINGLE MODULE
MULTIPLE
MAX. BAUD RATES REQUIRED.
MIN. 19200
MODULE REDUNDANCY
YES
BUS REDUNDANCY
YES
PARAMETER/SEC
MAX. 1 SECOND WITH
ANY TYPE OF MIX.
CONFIGURATION
TOTAL CAPACITY
COMMUNICATION
WITH
ESTABLISHED GIVE THE NAMES OF
ESD SYSTEMS FOR
WHICH DCS VENDOR
HAS
ESTABLISHED
COMMUNICAITONS SO
FAR
TOTAL LOADING FOR CONFIGURED
<30%
TAGS
FUTURE MARGIN
>50%
LIMITATIONS
NO
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
SPECIFICATIONS FOR
DCS
Page 113 of
124
OTHER FEATURES
34
COMMUNICATION
AND PLC
35
WRITE BACK TO PLC FROM DCS
36
DCS CLOCK
37
BETWEEN
DCS DCS
BIDDER
TO
COORDINATE WITH PLC
BIDDER
FOR
ESTABLISHING
COMMUNICATION
BETWEEN DCS AND
PLC AND CONFIGURE
REQUIRED INTERFACE
/ TAGS / DISPLAYS
/DATABASE ETC.
YES , WITH SECURITY
FEATURES. HOWEVER
THIS FEATURE SHALL
NOT BE USED.
TIME SYNCHRONIZATION METHOD
WITH PLC
YES
STABILITY OF CLOCK
+/- 1 SEC OND PER
DAY
TEMPERATURE EFFECT
MIN.
ALARMS SEQUENCE
MAX. NOS. OF PROCESS ALARMS
MIN. 10,000
MAX. NOS. OF SYSTEM ALARMS
MIN. 5,000
SEGREGATION OF PROCESS AND YES
WITH
DIFF.
SYSTEM ALARMS
COLOUR/PRIORITY/HO
OTER SOUNDS
APPEARANCE
OF
ALARMS
SEQUENTIAL MANNER
IN YES WITH 1 SECOND
TIME STAMP
TIME AND DATE STAMPING WITH 1 YES
SEC. RESOLUTION
PRINT OUT OF CURRENT
HSITORIZED ALARMS
AND YES
FULLY CONFIGURABLE
ALARM DISPLAYS
STD. YES, WITH WINDOWS
TYPE FEATURE WITH
ALL GUI FACILITIES
OR
TOTAL NOS. OF ALARM PAGES
MIN. 25
MAX. NOS. OF ALRMS PER PAGE
MIN. 20
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
TOTAL NOS. OF SYSTEM ALARM
PAGES
MIN. 25
MAX. NOS. OF ALARMS PER PAGE
MIN. 10
SPECIFICATIONS FOR
DCS
Page 114 of
124
TOTAL NOS. OF PROCESS ALARMS IN MIN. LAST 500 NOS. OF
RECENT ALARM LIST
ALARMS
TOTAL NOS. OF SYSTEM ALARMS IN MIN. LAST 250 NOS. OF
RECENT ALARM LIST
ALARMS
LAST IN FIRST OUT PATTERN IN YES
PROCESS AND SYSTEM ALARM
STORAGE IN REAL TIME AND
HISTORY.
SORTING OF ALARMS BASED ON
TAG , PRIORITY, OCCURANCE, ETC.
YES
MULTIPLE ACKNOLEDGEMENT OF YES
ALARMS WITH SINGLE KEY STROKE
GLOBAL ACKNOWLEDGEMENT OF
ALARMS
YES , FROM ANY WORK
STATION
DIFF. PRIORITY AND TONES
YES , MIN. 4 PRIORITY
LEVELS WITH DIFF.
TONE FOR PROCESS
AND SYSTEM ALARM
COLOUR STATE CHANGE IN ALALARM YES , MIN. 2 STATE
OCCURANCE AND
COLOUR CHANGES
ACKNOWLEDGEMENT
ALARM ENABLING AND DISABLING IN YES
A LOOP RUN TIME
ALARM VALUE CHANGES IN RUN
TIME
38
YES
PASSWORD
PROTECTION
ABOVE CHANGES
FOR YES
LATCHED
TYPE
ALRMS
PROCESS AND SYSTEM
FOR YES,
WITHOUT
OPERATOR
INTRVENTION,
IT
SHOULD
NOT
DISAPPEAR
FROM
ALARM DATABASE
OPERATOR ACTION JOURNAL WITH YES,
SEQUENTIAL
TIME DATE STAMP
RECORING
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
39
MAX.
NOS.
RECORDABLE
OF
40
GRAPHICAL USER INTERFACE
SPECIFICATIONS FOR
DCS
Page 115 of
124
CHANGES MIN. 10,000
GRAPHIC BUILDING WITH MOUSE AND YES
KEY BOARD
STANDARD GUI BASED WINDOWING
GRAPHICS
TOTAL
NOS.
SUPPORTED
OF
YES , LIKE XWINDOWS,
OPEN LOOK, MOTIF OR
WINDOWS NT GUI
COLOURS MIN. 16 MILLION
TOTAL NOS. OF DIFF. SIZE OF FONTS MIN. 16
SUPPORTED
TOTAL NOS. OF DIFF. SIZE OF LINE MIN. 4
THICKENS SUPPORTED
DRAG AND DROP WITH EDIT, COPY YES
CUT, PASTE FEATURE
LIBRARY FACILITIES FOR SYMBOLS
YES, AS PER
S5.X/IEC1131
ISA
IMPORT / EXPORT OF GRAPHICS IN YES
OTHER GRAPHICS
STANDARD SYMBOL LIBRARY AS
PER ISA
FREELY
FEATURE
SIZABLE
YES
WINDOWING YES
MAX. NO. OF WINDOWS ON A SIGNLE MIN. 4
OPERATOR STATION
OVERLAYING FEATURE
YES
MAX. NO. OF OVERLAYS ON A
SINGLE GRAPHIC
NO LIMIT
MAX.. NO. OF ALL TYPES
DYNAMIC POINTS PER DISPLAY
MAX. NOS.
GRAPHICS
OF
USER
OF NO LIMIT
CREATED NO LIMIT
MAX. FILE SIZE LIMIT OF A GRAPHIC
NO LIMIT
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
SPECIFICATIONS FOR
DCS
Page 116 of
124
STANDARD GRAPHICS LIKE SYSTEM YES
DIAGNOSTICS ETC.
ON LINE CONTEXT SENSITIVE HELP YES
FOR GRAPHIC BUILDING
ANY PROGRAMMING LANGUAGE YES
SUPPORT BY GRAPHICS
STARTING OF USER PROGRAM FROM YES
GRAPHIC PANLE / SOFT
TARGETS
CUSTOMIZED , COMPLEX GRAPHICS YES
FOR MANIPULATING CONTROL
STRATEGIES BY OPERATOR
GLOBAL CHANGES FOR A GRAPHICS YES, WITHOUT ANY
AT SINGLE LOCATION WITH SINGLE MANUAL COPY/PASTE
COMMAND
COMMANDS TO OTHER
OPERATOR STATIONS
MEMORY RESIDENT GRAPHICS AT
WORKSTATION
41
MAX
TRENDS
REAL TIME TRENDS
YES
HISTORIAN TRENDS
YES, MIN. 2000 TAGS
AT 1 SECOND, MIN. 1000
TAGS AT 2
SECOND AND MIN. 2000
TAGS AT 5 TO 10
SECONDS.
THERE
SHALL NOT BE ANY
DATA RETENTION LIMIT
EXCEPT HDD SIZE FOR
ALL
HISTORICAL
TREND DATA
ZOOMING OF TIME AND VALUE AXIS YES
OF TREND
MIN. TREND TIME RESOLUTION WITH 1 SEC. MIN. 1 HOUR IN
MIN. SPAN IN REAL TIME
REAL TIME
ANY PARAMETER / SYSTEM TAG CAN YES
BE TRENDED FOR REAL TIME AS
WELL AS HISTORIAN
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
SPECIFICATIONS FOR
DCS
Page 117 of
124
TUNING OF A LOOP IS SUPPORTED BY YES
INPUT , SET POINT AND OUTPUT
TRENDING
SIZE OF A TREND PAGE GRAPHICS
QUARTER/HALF
AND
FULL SCREEN, USER
CONFIGURABLE
MAX.
NO.
OF
PARAMETERS MIN. 6
SUPPORTED IN ONE TREND PAGE
DIGITAL VALUE OF PARAMETER WITH YES
GRID SELECTED TIME BASE
FOR ANY PARTICULAR TIME
TREND REFRESH RATE
1 SEC.
EFFECT OF NOS. OF TREND NO EFFECT
PARAMETER ON A SINGLE TREND
PAGE , ON TREND REFRESH RATE
TREND DISPLAY CALL UP TIME
1 SEC.
RUN TIME TREND PEN ASSIGNMENT YES
OF ANY TAG.
USER CONFIGURABLE TREND FOR YES
ANY RANGE THROUGH OUT THE
SPAN
42
MAX. REAL TIME TREND DEPTH OF
ANY PARAMETER WHICH IS NOT
CONFIGURED IN HISTORY
MIN. 1 HOUR WITH 1
SECOND SAMPLING
RATE
TREND UPDATE VALUE dB IS USER
CONFIGURABLE
YES
HISTORIAN
TOTAL NO. OF HISTORIAN POINTS SYSTEM TAG
SUPPORTED BY THE SYSTEM
MIN. SCAN TIME PER POINT
1 SEC. FOR MIN. 200O
TAGS, 2 SECONDS FOR
MIN. 1000 TAGS, 5 TO 10
SECONDS FOR MIN.
1000 TAGS . TOTAL
HISTORIAN SIZE SHALL
BE MIN. 5000
AVERAGING , MIN. MAX. AND OTHER YES
MATH FUNCTIONALITY AVAILABILITY
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
PRESENT HISTORIAN LOAD
40%
FUTURE MARGIN IN HISTORY
60%
SPECIFICATIONS FOR
DCS
Page 118 of
124
ANY ATTRIBUTE OF ANY PARAMETER YES
(TAG) CAN BE
HISTORIZED, LIKE PV ,MV,SV,ALARM
FLAG, DIGITAL INPUT,OUTPUT,BAD
VALUE FLAG,ETC..
RETENTION TIME FOR ALL THE
POINTS AT 1 SEC.
NO TIME LIMIT, EXCEPT
THE HDD SIZE
RUN TIME ADDITION OR DELETION OF YES
ANY TAG IN HISTOYR
EFFECT
OF
SYSTEM
TIME NO LOSS OF DATA
ADJUSTMENT , BACK AND FORHT ON
HSITORIAN DATA
43
2ND HDD REQUIREMENT
ON ALL THE STATIONS,
WHERE
HISTORIAN
TREND, LONG TERM
LOG/REPORT,
ETC.
ARE STORED, WILL BE
QUIPPED WITH 500 GB
RAID-I HDD WITH HOT
SWAPPABLE FEATURE
ANY OTHER LIMITATION
NO LIMIT
REPORTS / LOGS
MAX. POINTS/TAGS PER REPORTS
NO LIMIT
MAX. NO. OF USER CONFIGURED
REPORTS
NO LIMIT
TYPE OF REPORTS
SNAP
SHOT,
HOURLY,SHIFT,DAILY,
WEEKLY,
MONTHLY,
AND USER SCHEDULED
INTERVAL ,ETC.
ON
DEMAND
REPORTS YES
GENERATION AND PRINTOUT AT ANY
TIME FOR ANY TYPE OF REPORTS
REPORT DEVELOPING TOOLS
MENU DRIVEN , GUI
BASED
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
HISTORY/
SUPPORT
REAL TIME REPORT
MATH.
CAPACITY
WRITER
IN
SPECIFICATIONS FOR
DCS
Page 119 of
124
YES
REPORT YES
REPORT RETENTION TIME
NO LIMIT EXCEPT HDD
SIZE
REPORT ARCHIVE ON DAT
YES
,
NO
AUTOMATIC
REPORT ARCHIVE ON 3.5" FLOPPY
YES , AUTOMATIC
REPORT FILE FORMAT
MICROSOFT
EXCEL
LATEST VERSION. ALL
OPERATOR
AND
ENGINEERING
STATIONS SHALL BE
EQUIPPED WITH MS
OFFICE LICENSE
COPY.
CUSTOMIZED REPORT
YES
LIMIT,
CUSTOMIZED REPORT SCHEDULE , YES
RUNNING AT MIN. OF 1 MIN.
INTERVAL
44
SYSTEM DIAGNOSTICS
I/O MODULE
YES ,
UPTO
IND.
CHANNEL STATUS
CONTROLLER
YES , INCLUDES ALL
MODULE, COMPRISING
OF CONTROLLER SUB
SYSTEM
MAIN FILE SERVER
YES, INCLUDING ALL
LOCAL PERIPHERALS
ALL PERIPHERALS
YES,
ALL
GLOBAL
PERIPHERALS
ANY TYPE OF MINOR SOFTWARE AND YES
HARDWARE ERROR
ROUTINE SYSTEM DIAGNOSTICS
YES
ANY INTERNAL OR EXTERNAL COMM. YES
ERROR, INCLDING BUS FAILURES
MAJOR HARDWARE FAILURE
YES
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
MAJOR SOFTWARE FAILURE
YES
SYSTEM REDUNDANT COMPONENT
CHANGEOVER
YES
ON LINE HELP FOR ALL TYPES OF
FAILURES
YES
SYSTEM MODULE DYNAMIC LOAD
INDICATIONS
YES
SPECIFICATIONS FOR
DCS
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124
ANY OTHER TYPE OF DIAGNOSTIC
OFFERED
45
SYSTEM SECURITY LEVEL
LEVEL-1
OPERATOR
LEVEL-2
SUPERVISOR
LEVEL-3
ENGINEER
LEVEL4
SYS. ADMINISTRATOR
46
SYSTEM BATTERY BACK UP TIME FOR MIN. 72 HRS.
DATA HOLD
47
COMPLETE SYSTEM COLD START UP MIN.
TIME
48
SYSTEM SELF BOOTABLE
YES , WITHOUT ANY
USER INTERVENTION
WITH ALL DEFAULT
PERSONALITIES,
IMAGES
AND
LAST
CHECKPOINTED
DATABASE
49
INTELLIGENT I/O
YES
50
UNIVERSAL I/O
BONUS
51
I/O SIGNAL SEGREGATION
I/O TYPE
YES REQUIRED FROM
MARSHALLING PANEL
LEVEL
AND
DCS
SYSTEM HARDWARE
PANEL LEVEL
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
PLANT UNIT AREA
SPECIFICATIONS FOR
DCS
Page 121 of
124
YES REQUIRED FROM
MARSHALLING PANEL
LEVEL
AND
DCS
SYSTEM HARDWARE
PANEL LEVEL
52
OPTIONAL SOFTWARE QUOTED AS
NOT ALLOWED
AGAINST OUR STD. SOULUTION
REQUIREMENT
53
OPTIONAL SOFTWARE QUOTED AS BIDDER TO HIGHLIGHT
EXTRA
FEATURE
/SYSTEM ALL SUCH FEATURES
ENHENCEMENT, WHICH ARE NOT
INCLUDED IN ENQ. SPECS.
54
SPARES QUOTED FOR TWO YEARS YES, WTH UNIT PRICE
TROUBLE FREE OPERATION OF THE
COMPLETE SYSTEM
55
NOS. OF CABINETS
SUFFICIENT
TO
ACCOMMODATE ALL
H/W , AS SPECIFIED.
MARSHALLING/PDB/SY
STEM CABINET SHALL
BE
AS
PER
SPECIFICATIONS AND
QTY SHALL BE AS PER
OWNERS
GUIDELINES/REQUIRE
MENT SPECIFIED IN
THIS COMPLETE ENQ.
DOCUMENT
56
MAKE / MODEL OF CABINET
RITTAL / MODEL: 4108
WITH
ALL
OTHER
ACCESSORIES
AS
MENTIONED IN ENQ.
SPECS 1200MM(W) X
800MM(D)X 2100MM(H),
RAL 7032 COLOUR
SHED, ALL IDENTICAL
57
INTERNAL WIRING OF PANELS
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
DIGITAL
/COLOUR
58
59
INPUTS
SPECIFICATIONS FOR
DCS
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124
WIRING SIZE 1.0 SQ. MM MULTI
STRAND
,
SILVER
COATED , TEFLON
INSULATED/STD
DIGITAL
OUTPUTS
SIZE /COLOUR
WIRING
1.0 SQ. MM MULTI
STRAND
,
SILVER
COATED , TEFLON
INSULATED/STD
ANALOG
INPUT
SIZE / COLOUR
WIRING
0.75 SQ. MM MULTI
STRAND
,
SILVER
COATED , TEFLON
INSULATED/STD
110 V AC SUPPLY WIRING SIZE /
COLOUR
MIN. SIZE SHALL BE 2.5
SQ.
MM
,
MULTISTREND,
COPPER WIRE/STD
24 V DC SUPPLY WIRING SIZE /
COLOUR
MIN. SIZE SHALL BE 2.5
SQ.
MM
,
MULTISTRAND,
COPPER WIRE/STD
INTERPOSING RELAYS
MAKE AND MODEL
OMRON MAKE, 24 V DC,
SOCKET MOUNT, 4
NO/NC
WITH
LED
INDICATION FOR COIL
SUPPLY VOLTAGE
24 V D.C.
CONTACT RATING
24V-240 V DC/ A.C. / 5
AMP
INBUILT DIODE/LED
YES
NOS. OF CONTACTS
4 NO/NC
BY-PASSING ARRANGEMENT
NO
MOUNTING ARRANGEMENT
PLUG-IN TYPE / SOCKET
DIN RAIL
MOUNTED
OTHER LIMITATIONS
NO LIMITATIONS
TYPE OF TERMINATIONS
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
ANALOG INPUT
SPECIFICATIONS FOR
DCS
Page 123 of
124
0.5 TO 4.0 SQ. M.M.
WIRE
SUITABLE,
MELAMINE MATERIAL
OF
WAGO
MAKE,
SCREW LESS,
SIDE/SIDE ENTRY TYPE
All rights reserved
DCS SYSTEM FOR DAROU-1 SULPHURIC ACID PLANT
AND ITS UTILITY AT ICS INDORAMA, SENEGAL,
WEST AFRICA
SPECIFICATIONS FOR
DCS
Page 124 of
124
ANNEXURE-V
ARCHITECTURE
All rights reserved