PLC Details of Agc Plant

TECHNICAL SPECIFICATIONS FOR NOTICE INVITING TENDER FOR THE SUPPLY OF PLC BASED CONTROL SYSTEM FOR ASSOCIATED
GAS COMPRESSOR PLANT

OF
RASHTRIYA CHEMICALS AND FERTILIZERS LTD., CHEMBUR, MAHUL ROAD MUMBAI-71
JUNE-2013
Page 1 of 93
CONTENTS
SECTION I II TITLE GENERAL SYSTEM AND TECHNOLOGY REQUIREMENTS FUNCTIONAL REQUIREMENTS OF PLC BASED CONTROL SYSTEM CONFIGURATION AND TECHNICAL SPECIFICATIONS OF PLC BASED CONTROL SYSTEM INFORMATION FROM PLC BASED CONTROL SYSTEM VENDOR SCOPE OF SUPPLY AND SUPPORT SERVICES PREQUALIFICATION CRITERIA AND PLC BASED CONTROL SYSTEM SYSTEM ACCEPTANCE CRITERIA CONDITIONS AND REQUIREMENTS OF BIDDING OVERVIEW OF SCOPE OF SUPPLY PAGE NO. 03 11
III
34
IV V VI
49 60 69
VII VIII
72 78
Page 2 of 93
CHAPTER I GENERAL SYSTEM AND TECHNOLOGY REQUIREMENTS
Page 3 of 93
OVERALL REQUIREMENTS- SYSTEMS AND TECHNOLOGY

1.1 INTRODUCTION
Rashtriya Chemicals and Fertilizers Limited, owns and operates manufacturing facilities for various fertilizers and industrial chemicals at its units at Trombay and at Thal in Maharashtra State, India. In Trombay Unit there is a turbine driven two stage high pressure compressors of M/s Kawasaki Heavy Industries, Japan of 22500 Nm3/Hr capacity. Its suction pressure is 9.2 kg/cm2 and temp. is 40 deg.C. Its first stage pressure and temp. are 21 kg/cm2 and 126 deg.C respectively and second stage discharge pressure and temp. are 43.5 kg/cm2 and 106 deg.C respectively. High pressure compressor is driven by back pressure turbine. The final discharge gas is supplied as a process gas to Ammonia-I, Ammonia-V and Methanol plant. It is proposed to replace existing Electro-Pneumatic control system. Hazardous area classification for Associated Gas Compressor plant is Zone 2 Gr.II C.
1.2 BACKGROUND
Presently Electro-pneumatic Relay based is used in the plant for monitoring and control. The safety interlock logic system is implemented through discrete Relays. Conventional Pneumatic vertical panel for operators are located in the control room. It is proposed to replace existing control system with state of the art PLC based control system. The system incorporate trip interlocks as well as Analog controls inclusive of Customized Anti-surge control logic related to the process of the plant.
1.3 SCOPE
This specification covers general requirements for the PLC based control system & its auxiliary equipments to be supplied for the above project. The scope includes design of system hardware, software, spares, Manufacturing , testing at factory(FAT) & at site(SAT), documentation, training, erection & commissioning of control system, system integration, maintenance contract & other necessary items to make the system operable & complete to the satisfaction of owner. Offers are to be submitted for the two options separately system as illustrated in schematic diagram for proposed:
Page 4 of 93
COMPRESSOR HOUSE
COMPR B
COMPR A
LCP
LCP
TRANSPORTATION /WALKWAY
AIRCONDITIONE R ROOM
SYSTEM ROOM
WAY FOR Ethernet approx..50 Mtrs.
SCHEMATIC DIAGRAM FOR LOCATION OF SYSTEM ROOM & LOCAL CONTROL PANEL(LCP) FOR ASSOCIATED GAS COMPRESSOR PLANT
Transportation of system cabinets, other cabinets, operating/engineering stations, Annunciator panels to Associated Gas Compressor plant control room shall be done by vendor.. Unpacking of all cabinets.Storagecabinets, Storage of cabinets inside system room before start of shutdown and positioning/fixing of panels, Disposal of wooden packings to RCF scrapyard scrapyardon frames, shall be done by vendor. glanding of interpanel wiring,cable termination.
Formatted: Underline, Font color: Black, English (United States) Formatted: Underline, Font color: Black, English (United States) Formatted: Underline, Font color: Black, English (United States) Formatted: Underline, Font color: Black
Page 5 of 93
Vendor shall perform on site testing (OST) before making power on. Detail schedule of activities pertaining to OST shall be approved during kickoff meetings. Actual plant shut down time available shall be a maximum of 5 days. The PLC based control system contractor has to commission the system working round the clock in this period only. It is to be noted that switching from existing pneumatic control system to new PLC based control system within minimum span of time is the essence of work. The vendor shall supply all PLC based control system equipment, input/output panels, complete with marking of cables and internals. It is also within the vendor's scope of supply to perform all the necessary application programming including the development of graphicprocess graphic process flow sheets, trends, control groups etc. The PLC based control system and the various panels shall be designed, manufactured and tested in accordance with this specification and the relevant Instrument Data Sheets and documents. During detailed engineering work, building of graphics, the vendor is obliged to integrate involve the owner's personnel in order to ensure a smooth hand over of the PLC based control system. This should include training in maintenance and reconfiguration of the system. The vendor is obliged to participate in installation on site. RCF shall furnish following information to vendor for application development: 1) Documentation of Input/ Output database as hard / soft copy 2) Documentation of wiring diagram/ write-up/ logic/ sequence/ control logic/process interlocks. 3) Approval of documents/formats as identified during Kick Off meeting
Formatted: Font: Bold, Font color: Black, English (United States) Formatted: Font: Bold, Font color: Black, English (United States) Formatted: Font: Bold, Font color: Black, English (United States)
1.4 TECHNOLOGY AND OBSOLESCENCE

The PLC based control system to be supplied shall incorporate advance state of art technology that shall guarantee freedom from obsolescence at least for 15 years. Furthermore, the intelligence shall be extensively distributed up to the field level. The PLC based control system to be offered shall be the latest in last 3 years & in the ongoing the product range of the foreign principal of the supplier/OEM. The bidder shall certify that the product offered is the latest and proven in their PLC based control system family. Any impending product launch shall also be indicated in the bid, along with features for up gradation compatibility. The offer is liable to be rejected if the system offered is not the vendor's latest PLC based control system product or if prior information is not furnished about impending launch of a new system. Page 6 of 93
Formatted: Font: 14 pt, Font color: Black
1.4.1
Use of standard Procedures:
a) The system shall be composed of manufactures own standard hardware, systems software which can be configured to meet the stated requirements. b) Vendors standard operating system software shall not be modified to meet any of projects requirements. c) The vendors system shall be designed in a manner such that the implementation of application software requires no modification to the system operating software.
1.4.2
Field Proven Systems
All hardware, software and firmware supplied with the system shall have been field proven prior to placement of order; Field proven is defined as successful operation at a field installation of 24 or more months. a) This requirement does not apply to the application software to be developed for the project. b) Vendor shall guarantee that he will support all system hardware and firmware with spare parts and service for a period of 15 years from placement of order or 10 years from end of warranty, whichever period ends last.
1.4.3
Distributed / Open Architecture
The PLC based control system shall permit control, data acquisition and control functions to be performed at remote locations while providing the capability to monitor and control the distributed functions from a central control facility. The system shall be sufficiently flexible so that it can be configured to a wide range of process requirements at the loop and component level without changes to the hardware. The PLC based control system shall be based on on open system architecture. The open capabilities shall also allow third party software (such as operator interface, optimisation software or expert systems) to be an integral part of the systems when RCF intends to procure them. Communications with other devices shall be via industry standard protocols. System shall be capable of hosting various industry available communication protocols with third party systems. System shall be capable of installing communication module/ software in future.
1.4.4
Spare Capacity and Expansion Capability

Page 7 of 93
The PLC based control system shall be delivered to the installation site with the following minimum spare capacity and expansion capabilities. A) Spare Capacity a) b) Redundant capacity is not considered to be spare capacity. Process I/O racks shall contain 20% installed spare with fully wired all I/O modules. The module types shall be provided in the approximate ratio of non spare types and distributed throughout the I/O racks. Other system components to support the spare I/O such as Process I/O power supply capacity, terminal block, I/O cables, I/O communications, etc., shall also be installed with 20% spare capacity. If terminal blocks are pre wired to the process I/O then these shall also be pre wired to the spare I/O. Process I/O racks shall have an additional 20% spare rack space in each type of IO rack for further addition of any type of I/O card in corresponding I/O rack in future. only, without installed modules. This space shall be used for installing any type of modules of any mix. Process control device shall be sized such that no more than 60% of processing capability and memory is utilized. Vendor has to submit the CPU loading calculation. Cabinet, which contain terminal blocks, shall be provided with 20% spare terminal blocks . and space to install additional termination corresponding to utilization of spare rack space by addition of corresponding I/O cards.. Expansion Capabilities The system design shall include the capability for at least 25% future hardware expansion (relative to the bid), which shall be achieved by addition of equipment, without modifying or replacing existing equipment, communications cables or system operating software. This is in addition to the spare requirements of section 1.4.4 a) Each installed communication system shall have 25% node expansion capability for future development and still be capable of meeting the requirements of this specification. The vendor shall provide estimated loadings of the communication systems to substantiate this requirement. The system processing and memory capacity shall have 50% expansion capability for future application programming and configuration including, but not limited to, the following: Alarming / Monitoring, Equipment Monitoring, Trend and history collection, Reports, Displays including user defined graphics displays. Page 8 of 93
c)
d)
e)
B) a)
b)
c)
The PLC based control system shall be delivered to the installation site with the following minimum spare capacity and expansion capability.
1.4.111.4.5
Software Protection
No software locking mechanisms, which would restrict the user from copying the software source or compiled executable code from the storage media, shall be employed. No software locking mechanisms, which restrict the user from booting (starting Up), shall be employed. This means that no key disks or password or USB dongle shall be required to use the software supplied as part of the system for process control and for Engineering configuration. Operational security is different than software protection. User programmable operational securities to be provided at various levels of PLC based control system configuration
1.4.121.4.6
a)
Software Revision Levels
The vendors standard system operating software delivered to the installation site shall be the most recent field proven revision level available at the beginning of the Pre Factory Acceptance Test (FAT) which is applicable to the system hardware. The system shall allow for upgrading of system operating software on all redundant modules of the system without necessity of shutting down the process, without losing the window to the process (operator interface) and without losing any control functions.
b)
1.4.131.4.7
Third Party Equipment
All equipment provided as part of this system that is not manufactured by the Vendor shall be latest model of of current manufacture by the original equipment manufacturer Vendor at the time of placement of contract or order, that is, it shall be currently available for sale from the original manufacturer at the time of placement of contract or order. All such equipment shall meet all applicable project specifications and standards referenced in this specification.
1.5
OPEN ARCHITECTURE DESIGN

Page 9 of 93
The PLC based control system to be offered shall conform to open architecture design.
1.5.1
Ethernet
It shall have provision of IEEE 802.3, Deterministic and Real Time Redundant Ethernet 100 MBPS and TCP /IP protocols for communicating with MIS systems, controllers, operator & engineering stations printers, third party devices. Ethernet shall have capabilities to detect & self-rectify faults for undeterred communication to various intermediate nodes on network. Extension of Ethernet for provision of operating stations/Remote I/Os shall be implemented through Fibre Optic cable.
1.5.2
Migration
Migration to open standards as stipulated above shall be possible at the modular level (for each node on the system highway) and shall be achievable with the minimum of hardware.
1.5.3
Conformance
Conformance / seamless migration to oOpen architecture is an important requirement of this tender. Failure to comply with these specifications or failure to indicate a cost effective and seamless migration to open architecture would make the offer liable to be rejected. 1.6
PROVENNESS OF THE SYSTEM
The system to be offered shall be a proven system which shall already be installed and in operation at least for three years in India in a continuous process industry for similar operation of turbo compressor. The bidder shall submit details of such installations with references of the companies, size, value of orders, no. of years in operation etc. and contact persons name communication details. The bidder shall have had competent and proven expertise in supply, commissioning and servicing of comparative control system in India. Details regarding commissioning/service personnel & training facilities essentially needs to be provided by the vendor. . A service office in Mumbai shall be essentially preferred and bidder to provide the details of Mumbai service organization like No. of service engineers and customers being supported in Mumbai Region.
Page 10 of 93
CHAPTER II FUNCTIONAL REQUIREMENTS OF PLC BASED CONTROL SYSTEM

Page 11 of 93
2. FUNCTIONAL REQUIREMENTS OF PLC BASED CONTROL SYSTEM

PRECEDENCE OF SPECIFICATIONS
The objectives and broad guidelines laid down in this section define end goals of the purchase of the system. This Section of this NIT shall prevail over all subsequent sections. The supplier shall therefore be guided by these stipulations and in the event of a conflict between this section and any item in the subsequent sections; those given in this section shall prevail.
Formatted: Font: 16 pt, No underline, Font color: Black
2.1 CONTROL FUNCTIONS

All the controllers shall have built in redundancy function with high speed communication link between primary and secondary controllers. Controllers shall support Ethernet communication with operator/engengineeringg./server stations. All the controller modules shall be capable of performing at least the following functions however not limited to: a) Data acquisition from I/O modules. b) Regulatory PID control with different types (both direct & reverse acting
type)
c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s)
Ratio control ,sequence control Cascade control Feed forward control Anti-reset windup Lead-lag control, Time lag Arithmetic function like +,-, X, /, etc. Auto <--> manual bumpless transfer. Manual output ramp Logic functions like AND, OR, NOT, EXOR etc. High, low selector functions. Characteriser block Alarm setting of different parameters and masking of individual alarms with out changing the alarm set points. Displaying of the tuning parameters and facility to tune the close loop with a trend window so as to observe the loop performance etc. Square-root extraction/flow totalizer Input signal conditioning Adaptive control, Auto tuning. Antisurge control algorithm for 2 stage centrifugal compressor Pressure/temperature compensation for flow
All the above control functions shall be available in the form of algorithms and it shall be easily (software) configurable by the user. The PLC based Page 12 of 93
control system shall have the capability of converting various input signals into types, which are of direct use to the system. The functional block configuration should be kept to max. 50% and data acquisition cards to max. 70%. The total system loading for controller and data acquisition subsystem shall not exceed 60%. The loading indicated here is the worst case of high system activity referred to the use of memory, CPU time and communication capacity for the sub-system. Complex loops: Algorithms for these shall be written along with the purchaser. Built in redundancy is required for following: Closed loops/: Processor/controller Memory Power supply Data highway communication System bus AI/AO/DI/DO cards I/O Bus with controller Open Loops: Processor/controller Memory Power supply Data highway communication System bus I/O Bus with controller Server grade for MMI:
---- 1:1 ---- 1:1 ---- 1:1 ---- 1:1 ---- 1:1 ---- 1:1 ---- 1:1 ---- 1:1 ---- 1:1 ---- 1:1 ---- 1:1 ---- 1:1 ---- 1:1 ---- 1:1
Failure of a single channel shall not lead to the loop to be taken to manual mode for operation as the whole concept of automatic control resulting in low availability of system. Redundant cards of every kind shall be kept on line all the time and shall take over in bump-less mannerinstantaneously and automatically in case of failure of the active card. Furthermore, any configuration changes made on active controller should be automatically & instantaneously copied to the redundant standby controller. Design must ensure that data integrity is maintained during switch over and no portion of data to be transferred is corrupted before and during switch over to the backup controller. In addition, vendor shall guarantee the non-existence of any non-redundant device whose failure might affect the whole systems operation or reduce the operators monitoring capability. The controller updating time shall be 0.1 to 0.5 seconds user definable) for all the loops connected to it. There shall be hot standby for each controller Page 13 of 93
and associated cards (such as memory card, communication, switch-over control card, etc.) and the standby shall take over smoothly in the event of failure of the working controller. The controller modules shall have redundant power supply. The communication from the controller shall be redundant. The controller should be capable of executing more than two (2) scan rates simultaneously. In case the controller does not have such feature, an extra controller to be provided per area / group. The controller should be equipped with additional redundant firewall between controller and process network safeguarding the controller from any unwanted data. Third party interface provision with necessary independent hardware (serial controller / Gateway)/ software for 3 serial interfaces shall be made available. It shall be possible to download the data contents of the controller on to a mass storage device and same shall be reloaded automatically on to the controller to prevent loss of data during prolonged power failures. The downloading / reloading operation shall be fast and shall be possible from any station console. Failure of any controller should be indicated / printed on operator / engineer station with audible / voice alarm and shall be displayed locally. The system should reboot itself automatically if the power is restored. The controller should have the output hold facility to maintain the last output value in case of failure of both the main / redundant controller. The I/O card shall also hold / be configurable to fail-safe condition in case of both main / redundant cards fail. Communication between controller and I/O cards shall be preferably of proprietary nature for software safety purposes. Controllers and I/O cards shall have separate physical identity. Process control & emergency trip interlock shall be incorporated in PLC based control system controller and not in communication controller. All logic operations and all regulatory and process monitoring functions shall be performed in same controller of PLC based control system. The plant Emergency shutdown system will be based on proposed interlock system with a minimum of manual / local control. All logic and sequence operation shall be checked from input to output by forcing / enabling various inputs/outputs during pre-FAT / FAT. All triop related I/Os shall be segregated in I/O assignment such that trip related I/Os shall be terminated in redundant cards. These cards shall not have I/Os which are not related to plant tripping. Set point and PV tracking shall be a standard feature. The controller shall be able to operate in manual, auto, cascade or computer mode. Mode changeover in either direction shall be procedure less and bump-less. It shall Page 14 of 93
be possible to change set point, tuning constants, controller mode, and controller configuration from operator / engineer station. When operating under external supervisory mode, controller shall be able to track computer generated set-point and hold last generated value in case of computer failure. In such a case, controller shall fall back on auto mode and continue to operate at last received set point, in general. Other options like pre-defined set-point operation and fail safe condition shall also be possible. On the resumption of computer, the controller shall not return to external supervisory mode automatically. Computer failure indication shall be provided on all stations . In cascade loops, primary controller shall be able to track the set point and output of the secondary controller when secondary controller is not operating in cascade mode. Rail powered type IS barriers of P&F shall be provided for all I/Os to comply with hazardous area classification (Zone 2, Group II A/B, T4) specified for Methylamine plant. Common Rail powered type IS barriers with two power feed modules with every set of rail for P & F make IS Barrier shall be provided for all I/Os to comply with hazardous area classification (Zone 2, Group II C, T4) specified for Associated Gas Compressor plant.
2.2 ALARM FUNCTIONS

The control system shall be capable of warning the operator of any abnormal process conditions or internal control system failures. When any process alarm occurs the operator shall be warned by an audible sound. Alarm sound shall not be produced by speakers of Operator Station PCs but by separate electrical Hooter. individually installed on all 3 operating station PCs. It shall be possible to acknowledge and silence the alarm from any station Once the display in the alarm has been accessed, the operator shall acknowledge the alarm by depressing the acknowledgment button / key. The audible signal might be turned off by a dedicated key. During start-up and shutdown of the plant, it would be convenient if the operator is able to mask certain groups of alarms which are not required. An alarm system at startup with such feature shall be preferred. Operator shall be able to enable/ disable every alarm individually. The system should also have capability to produce different type of alarms related to hardware and process. Certain alarms may require action by the operator. The alarm system should have the facilities to create an "Operator's Guide", in which the operator can find instructions to overcome operational problems identified by the alarm. A text message page shall be provided to communicate instructions to operator which will be accessible at single click of a button. Page 15 of 93
2.3 INPUT-OUTPUT SYSTEM

All the input output blocks / modules shall be mounted in a single / multi rack system connected to a common communication highway. All I/O cards shall be separate. The system shall support the following type of input and output signals. Configuration of I/O modules shall be through engineering station and not by local configuration in I/O card modules.
2.3.1 Inputs
a) b) c) d) e) f) g) as 4-20mA DC Based 2 wire & 4 wire 1 - 5 V DC All types of thermocouple /RTD /mV inputs converted to 4-20mAcurrent Pulse input Potential free contacts From special analytical instrument Capability to communicate with Vvarious communication ports such Modbus, RS 232, RS 485 etc. for digital communication with various devices in the plant i.e. analysers, optimisation system, PLC based control system etc. Suitable hardware/software shall be supplied on chargeable basis if required. It shall be required to develop the necessary software drivers for such devices in PLC based control system; the vendors should not withhold any information to other manufacturers regarding their protocol for developing interface between the two systems. PLC :All tripping interlocks shall be configured in ladder programming and not only through function block. DI & DO need to be indicated Online on ladder logic so as to facilitate common functions such as forcing/simulation/timer value change etc. Display of PLC in ladder logic is required for monitoring/manipulating all functions of PLC. Configuration in only sequence tables is absolutely not acceptable. Online changes in PLC ladder configuration shall be possible without holding controller execution or stopping PLC scanning.
2.3.2 Scan Time

Scan time for a closed loop shall be the cycle time taken by controller to read, analyse or manipulate the and process input, perform control calculations and update controller output for loops configured within the controllers. Scan time for an open loop shall be the cycle time taken by data acquisition system to read, analyse or manipulate the and process inputs and perform Page 16 of 93
computations of all open loops configured within data acquisition system. Forsystem for various controls and data acquisition parameters with the following or lesser better scan time shall be used.
Sequence of events recording is not required but first out indication is required. Vendor shall submit detail scan time calculations during initial technical offer failing which offer may be summarily rejected. Vendor shall submit documented copy of standard product catalog to support scan time calculations. Sufficient number of controllers/power supplies & other redundancies need to be offered as per the number of controllers. Close Loops : a) Close loops
250 msec.
or
better
Open loops : a) Analog Inputs (4-20 mA) b) Digital Inputs c) Temperature Inputs
: : :
500 msec. or better 50 msec or better 1 Sec or better

2.3.3 Outputs
a) b) 4 - 20 mA DC Potential free contacts controllable from operator stations for manual start/stop etc. Both latched and momentary contacts shall be available
Each input/output blocks / module shall be provided with, but not be limited to, following functions. a) b) c) d) e) f) g) h) i) Signal filtering Signal conditioning like square root extraction linearization etc. Alarm setting-low, very low, high, very high, on measurement, set point, output etc. Limit checking Bias Integration of pulse inputs from the flow transmitter. Data acquisition. Trending - Real & Historical. Pressure, Temperature, compressibility factor correction for flow inputs. Page 17 of 93
All the output cards shall be able to give the output values from -5% to +105% i.e. from 3.2 mA to 20.8 mA. The input/output blocks /modules may be of single I/O type or multi I/O type. All the input/output cards shall have configurable 2 wire/4 wire transmitter feature and supply power to the required transmitters/I-P converters. The actual input output requirement is listed below. All I/O systems shall have redundant power supply. The I/O redundancy for closed loop control shall be 1:1 in the case of multiple input/ outputs per card .
2.3.4 I/O Cards

The I/O cards shall be connected to the terminals by means of prefab cables. I/O redundancy is required for all the closed loops as well as certain critical loops. I/O cards shall have built in galvanic / optical isolation for input and output. I/O cards need not be HART compliant by Hardware/software. No special corrosion resistant coating are required as per NIT. Even though vendors can offer ,products with special coating. No special credit shall be given for any such product. All the field instruments are located in Zone 2 Gr.II C Class 2 Gr.IIC hazardous area. Suitable barriers shall be provided for Zone 2 Gr.II C Class IIC area classification. The input card shall perform all types of linearization viz. square root, T/C, RTD as per channel basis. The I/O card should also hold / configure to fail-safe condition in case of failure of both main / redundant card. The output card shall perform output scaling, direct / reverse output. Digital Input / Output cards shall have following features a) All the digital inputs shall be potential free contacts. Digital input card shall provide interrogation voltage to the input. b) All digital outputs shall be potential free contacts with contact rating 230V AC, 5A. Power supply 24 VDC shall be routed through REGULATED POWER SUPPLY 24 vdc IN SCOPE OF THE VENDOR. Individual I/O card shall have visual status display indication for healthy, card fault, communication healthy and communication fault.
Page 18 of 93
I/O card racks shall have expandability. The card rack shall not be loaded for more than 80 percent capacity. I/O cards shall be mounted in rack such that connections of 2 cards shall not overlap. Removal/testing at card screwed termination shall be possible without removal of other wires.
DI/DO coming from Annunciator cabinet shall be connected to system through Remote I/Os through Ethernet.
Formatted: Right: 0.25 cm
2.3.5 List Of I/O Count Sr. No. TYPE OF SIGNAL Actual Qty. 20% extra Total Redund ancy (YES/ NO) Barriers (YES/ NO)
1.0 1.1
1.2
2.0 2.1
2.2
Close Loop Analog 4-20 mA DC, Two wire Analog Inputs (AI) 4-20 mA DC, Two wire Analog Outputs (AO) Open loop Analog 4-20 mA DC, Two wire Analog Inputs (AI) K & J type Thermocouple (T/Cs)& RTD Analog Inputs (AI) converted to 4-20 mA signals using universal
13
16
YES
YES
13
16
YES
YES
50
10
60
NO
YES
50
10
60
NO
YES
Page 19 of 93
2.3 2.4
2.5
converter P&F make barriers Digital Inputs (DI) Potential Free Digital Outputs (DO) with relays Potential Free Digital Outputs (DO) directly to the annunciator
45 10
9 2
54 12
NO YES
YES NO
32
32
NO
NO
Following table indicates Remote I/Os (DI/DO) ,in case of Annunciator/pump control panel resides on ETHERNET, same quantity shall be deducted from the DCS DI/Dos if RCF opts for extended ETHERNET configuration. This optional item shall be offered separately by vendor.
2.0 2.4 2.5 a Remote I/Os (DI/DO) Digital Inputs (DI) Potential Free Digital Outputs (DO) with relays 45 33 No No No No
P&F make universal temperature converter/barrier shall be used for interfacing of thermocouples/RTDs. These barriers shall be programmable so as to select range, type (J/K T/C /RTD, etc.), output, etc. for each barrier individually. Necessary hardware for programming barriers such as an adaptor to connect to a PC/laptop and programming software shall also be provided. These barriers along-with other barriers required for DI, DO, AI, AO shall be installed on Power DIN rails. P&F make Power feed modules shall be used in redundant configuration so that each DIN rail segment shall have redundant power supply Distribution of a truly redundant fail safe 24 V DC power supply shall be vendors scope. For all redundant I/O cards, number of I/O channel shall be as per manufacturers standard. However, maximum number of channels shall be 16 for analog cards and 32 for digital cards. Separate modules to be provided for AI, AO, DI, & DO for open loop as well close Loops. All I/O cards shall have capability for redundancy. Even I/O cards for nonredundant open loops shall be such that they can be configured for redundancy in future if required. Page 20 of 93
Required numbers of input/ outputs are without spare capacity. All these input/ outputs cards shall be wired/ installed in the system.
2.4 OPERATOR STATION, QTY :QTY: 2 NOS.

Operators will monitor the process and initiate all control functions from operator stations. All monitors and keyboards of operator stations shall be identical. They shall provide colour graphic, control, and display and alarm functions. It shall be possible to change control assignments to allow control of any plant area from any operator station by using the appropriate password at various level. All engineering functions shall be possible from both the Operator Stations. Each operator station shall have direct independent access via dual redundant communication path to the controller and not via the Engineering station. Operator station make and acceptable is only Dell make server grade PC12th generation, RAID-5 Configuration. Server grade operating system -2012, RAM 8GB, HDD-500GB and dual redundant power supply with 24 LED monitor. As an optional item; for each operating station, Vendor shall provide CE 770 ATEN MAKE or equivalent USB KVM extender with deskew function. The automatic signal compensation and RS232 serial functionality allow access to a computer system from a remote USB console. Local & remote units connect at distances up to 300 mtrs. Each Node where history resides should be minimum RAID 5 harddiskhard disk configuration to ensure maximum availability of history. Operator station (also Engg. Station) shall be with latest WINDOWS based proven system. (Vendor shall furnish list of minimum one working systems in continuous process chemical/fertilizer/refinery industry for OS other than Window) The Operator station shall be provided QWERTY Keyboard & Mouse for navigation & operation. All displays shall be accessible from LED Monitor of the station connected to the same data highway. 24 LED Multicolour displays are required. Party shall offer their own HMI software. Third Party software is not acceptable. The system shall have flexibility in specifying or changing the tag numbers, descriptions, ranges, scale factors, or grouping in the various displays. Each display shall always provide the following features: a. Time of day in hours and minutes Page 21 of 93
b. c. d.
Date by day, month, year Year shall be displayed in 4 (four) digits, e.g.1999, 2001 etc. Page number, if multi-page displays are used. synchronised from one clock
All real time clocks in the system shall be source.
Each LED screen shall be able to display full alphanumerical tag no. of process variable. A min. of sixteen (16) digits shall be required for tag no. and min. 30 digits for process description as per example given below: Tag No. Description : : 20PIC1501 20T501 PRESSURE
When configured in operations mode, the operator shall be able to perform following main functions from these stations: a) b) c) d) e) f) g) h) i) Monitoring/controlling of the entire plant (Regulatory and Supervisory). Trend display, Alarm Display and print out Report generation Graphics capability Computation Multi window capability Dedicated alarm view availability while operating through graphics General Features
Pump remote/local & start/stop interlock logic, process tripping interlock shall be incorporated in PLC based control system and graphical presentation of logic shall be available on Screen. Pump Auto /Manual, local/remote pump selection shall be through local control panelauxiliary console. Pump running status (Red/green colour)shall) shall be available on PLC based control system. Existing Interlock diagrams shall be given to vendors along with Tagnames of associated field instruments. PLC based control system vendor shall incorporate the same in the controllers. Also, provision of Emergency plant trip push button along with its linking in interlock logic for initiating plant trip is required.
The details of the above functions are listed below:
2.4.1 Monitoring / Controlling

Dynamic Display of the entire parameters as given below shall be available: Page 22 of 93
a) b)
Overall view of the Plant. Area shall show the graphic & numerical values with Engineering units wherever applicable, each parameter (measurement, set point) and alarm status of each area of the plant. Group - shall include, apart from those mentioned in area display, the details of controllers and its alarm status. It shall provide the operator with a display of up to 8 control instruments per page in a format resembling a conventional control panel. In addition to controllers certain important indicators may be shown on group display. The group display shall represent a bar graph and other indications of each loops process variable, set point and output values. The group display shall include the group number and title, and short description for each loop or variable displayed. The mode of each loop (Manual/ Auto / Cascade etc.) shall be shown in the group display.
c)
It shall be possible to control process from group display. Following control actions shall be possible from group display. I. II. III. IV. Increase / decrease set point Change controller mode Change controller output in manual mode Start / stop or open/close command for digital points.
d) Loop - shall include the details mentioned in area & group displays and the complete loop details which include measurement, set-point, output values, mode of the controller, tuning parameters etc. It also shall include process variable minimum and maximum values, alarm set point, limits on set point, output & velocity, controller action(Direct/Reverse), computational constants like bias, ratio, integrated value (Total), Engineering units. Following actions shall be possible from Loop display. I. II. III. IV. V. VI. VII. Increase / decrease set point Change controller mode Change controller output in manual mode Start / stop or open/close command for digital points. Change tuning parameters Change limits on set point, output and Change alarm set point
velocity
There should be provision of conversion of QWERTY Keyboard buttons to dedicated function buttons to increase / decrease output / set point at fast rate (upto 4%)and slow rate (minimum 1%). Page 23 of 93
Also it shall be possible to increase / decrease output (in manual mode) / set point (in auto mode) from controller bar graph display faceplate by use of mouse pointer. In group/ loop displays controller tags shall have auto/ manual / cascade mode selection soft targets by default. This should not be an engineered solution. Loop display shall also contain a trend displaying Process value, Set value and Output with sample time of 1 second and full time scale of 60 minutes for tuning of process control loops. If changing of tuning parameters of PID loops requires additional software same shall be offered. Set point/ Output tolerance check- If Set point of a controller and its output in auto / manual mode is changed by 10% or more than its previous value system shall have facility to warn the operator and for ask for confirmation for such change. Warning shall be displayed so as to clearly indicate in bold. The system shall provide a screen update time not exceeding 1 sec. Any loop with high deviation or high low alarm shall be shown by a visual alarm. The operator shall be able to manipulate the set point, output, and control modes of any loops shown on a group display by the appropriate key entries. The operator shall be able to create and display groups in addition to those in overview display.
2.4.2 Trend Display

Trends shall be easily configured online through standard trend displays, without the need to build special displays. Real-time and historical data shall be presented together on the same trend. Archived history may be accessed automatically by simply scrolling to, or directly entering, the appropriate time and date. Users shall be able to copy trend data to other applications such as Microsoft Excel. The simultaneous historical trending of at least sixteen eight (816) selected variables shall be possible on any operating/engineering station with selectable scales and colours, per trend, and with selectable sampling rates (min. 1 sec) for all the AI, AO, DI & DO tags with minimum archiving period of 3 months. The real-time trending shall be available for all the parameters of all the loops of the plant. However, user shall have the flexibility to assign and reassign any of the loops to the real-time trend database. Page 24 of 93
The real-time trend shall have a minimum scan time preferably 1 sec and the display time frame shall be user definable from 1 minute to 2 hours. Duration of real time trend shall be minimum 30 days. Sampling rate shall be selectable. System shall provide history collection over a wide range of frequencies in both average and snapshot/production formats. Large amounts of history shall be retained online, with automatic archiving, allowing retention of and access to unlimited quantities of historical data. Archive data can be stored on a variety of storage devices, not other than following: Local or networked hard drives Optical media ZIP or JAZZ drives System shall store the values of points over time at regular intervals, between 1 to 30 seconds as well as averages of the 1-minute snapshots at intervals of 1 to 24 hours. The period of time that this historical data is stored shall be selectable. User shall be able to archive this process history to off-line media such a removable disk so that the history can be restored later if needed. It shall be possible to magnify the trend values by assigning a user-defined window with lower and upper limit of the trend value range (i.e. magnify a part of the trend screen). A vertical marker / pointer shall be possible on historical and real time trend to pinpoint the value at any point on the trend. Scrolling, windowing, digital value display at selectable sampling times and zooming features shall be provided. Trend display should indicate value & time on cursor movement.
2.4.3 Alarm Display

System shall provide comprehensive alarm and event detection, management, and reporting facilities to speedily target the source of the problem, allowing the operator to focus on the data of interest in times of urgency. Following features are required:
Controller-based alarming. Multiple alarm priorities. Standard notification displays of alarms, events, alerts, and messages. Most recent alarm zone displayed on every screen. Advanced alarm management such as the ability to: Launch associated graphic and point detail display on alarm for instant
context
Log the return to normal status
Page 25 of 93
Filter alarms (for example, by priority, asset, and acknowledgment status) Log to track operator-initiated actions Configure and view aggregate alarm counts
Alarm groups shall be available as an alternative way of viewing areas and alarms associated with areas. All stations shall have the facility to set the alarm limits (such as low, extra low, high, extra high etc.) for all the process variables as well as set point, output and deviation on the above three variables. System shall display the alarm conditions based on the above parameters. The Alarm Summary Display shall provide the operator with a summary of process alarms in an operator station group in an order of occurrence. The display shall show the following items for each point: a) Tag number b) Type of alarm (when point is in alarm) c) A description of the point d) Date and time of occurrence All the alarms shall be accompanied by audio/voice announcement till the same is acknowledged. It shall be possible to selectively silent any alarm from any station. The alarm condition shall indicate the point(s) in alarm by flashing red or reverse video character and/ or the tag number. Priority alarm & standard alarm conditions should be separated. When the alarm is acknowledged, the flashing display shall become steady. The display shall return to normal when an acknowledged alarm condition returns to normal. System shall have blinking facility for all the alarms. The alarm conditions shall be available in all the area, group & loop displays. Different audio tones shall be available to distinguish between different areas or types of alarms. Alarm/Event Printer, Qty.: 1 No. System shall print a summary of alarms and events to common alarm/event printer as and when desired. System Alarms System shall have capability of on-line self-diagnosis. Any abnormal conditions in subsystems shall be displayed as system alarm message on operator console irrespective of the display selected.
2.4.4 Colour Dynamic Graphic Displays

Page 26 of 93
These are the graphic displays showing graphically the process pipes, equipment, and relevant instrumentation. Each display shall be organised in order to show instrumentation for each process section and plant area. The following information shall be available from these displays: a) b) c) Measuring value of each analog variable Status of pumps, on-off valves etc. Alarm either for analog or digital variables
Graphic displays shall be interactive type through which it shall be possible to control the process. It shall be possible to send motor start/stop and shutdown/ motorised valve open/close commands from this display as per job specifications. It shall be possible to go from any graphic page to related graphic pages or any group display or alarm summary in single key stroke using soft key function. The graphics will be built by the vendor on the basis of P & I diagrams which will be supplied by R.C.F. It shall be possible to create new (custom) displays, which can include graphics and animations. Real time updating shall be possible for at least 125 data variables in each display. Dynamic updating shall include changing symbols (such as closed valve symbol in place of open valve symbol and vice versa, changing levels in vessels), change in colour, and change in values. The display call up time shall be less than 1 sec. for all dynamic graphic pages. It shall be possible to create, modify, and delete the graphics through interactive sessions on-line. The graphics modules shall enable creation of static (plant schematics) and dynamics (process variables). Standard building blocks / templates pertaining to a process industry like pipeline, valves, pumps etc. shall be provided and the user shall use these standard blocks to create graphics without the help of any programming language. It shall also be possible to add user defined symbols to the library of templates. The current values of process variables with engineering units shall be displayed in the objects. Abnormal conditions shall also be displayed in the graphics. Once a picture has been built, it shall be possible to add to any other picture/ pictures as sub picture. Scaling, scrolling and zooming of graphics shall also be possible. Number of graphic pages available should not be a limitation to adequately display the complete process.
2.4.5 Event Logging

Page 27 of 93
All event logs shall be displayable on any station and printed on separate Alarm/Event Printer. System shall store every event, such as a point status change or an operator action, in an event journal. Events shall be collected periodically in an online event database for queries and reporting. Event archiving operation shall be performed at appropriate intervals. System shall archive events to a network fileserver or to disk as desired. Events archived to a network fileserver can be copied to other media such as CD, or included in a system backup. All changes in the system caused by, for example, alarms, operator actions, and changes in security level shall be logged as events. All alarms shall be recorded in the event log, including when it was generated, when it returned to normal, and when it was acknowledged. On demand, a chronological record of events shall be displayed on any station between user-specified time periods. The pages of the log shall be scrolled and the log capable of being stopped at any time. It shall not be feasible for the operator to erase any part of the event log. Alarm/Event Printer System shall print a summary of alarms and events to an alarm/event printer as and when desired.
2.4.6 Report Generation

For analysing key system data, system shall provide a range of standard reports, including Alarm/Event reports for all alarms and events in a specified time period. By using filters, this report shall provide an operator and/or point trace facility. It shall be possible to design Excel-based Custom Reports, which can contain almost any kind of information stored in the server database. User can either request reports when you required or schedule system to automatically produce reports at pre-defined times. Outputs may be directed to screen, separate report printer or file. Following reports are required on demand as well as automatically at pre-set time. a) b) c) Shift/Daily/Monthly reports of different process variables. Hourly avg., hourly total, hourly max/min., instantaneous values of the process variables. The shift/ daily/monthly report shall be printed automatically to Page 28 of 93
d) e) f) g) h) i) j)
report printer at a specified time. But the On Demand report shall be printed with demand from operator station. Daily/Monthly reports showing raw material, utility consumption, production, etc. Energy consumption report for a section/total plant. Energy and mass balance and other analysis reports. System diagnostic reports in case of failure of any module / component of the system both current and historical. Management Information Reports. Log of operator initiated actions, on demand. Alarm and trip review reports.
The formats and other details of the various reports shall be designed in consultation with the purchaser. Apart from pre-formatted reports mentioned above, there shall be a report writer with SQL-like commands to retrieve and generate reports in user definable formats. Number of reports should not be a limitation. The reports shall have a configurable retention of generally 30 days and these shall not be overwritten / scratched by the subsequent reports. There shall be a spooling facility where the reports are preserved as spool files and can be queued to the printer at a later stage. There shall be facility for storage of above reports whenever required on a disk, CD, or included in a system backup.
2.4.7 Computation
The system shall have computational capabilities such as: a) b) c) d) e) Pressure & temperature compensation for compressible fluids Integration with the time (for flow measurement application) Transformation into different engineering units. Other standard chemical engineering functions User definable computations
These features are aimed towards facilitating the task of modifying the process variables updated to the database.
2.4.8
Process Engineering Environment
It should be possible to change the functionality of the Operator Station to Engineering mode through password. The functionality of the Station shall be logical and not physical.
Page 29 of 93
The environment for process engineering shall be largely menu-driven. Where developmental work is required to be done, involving programming and analysis, the user-friendly environment shall be provided.
2.4.9
System Software
Standard software The operating system of PLC based control system stations shall be based on WINDOWS only. All programs required for control and data acquisition, unit operation, alarm management, data communication and to define the system configuration and display content shall be provided. All the necessary utility programs, files and management tools necessary to format the data of disk / CD, copy files from one source to another, delete files, list the directory of files, and view or print the data within a file shall be provided. The system hardware and software shall allow the users maintenance staff to modify on-line the configuration, data grouping, descriptions, tag numbers, alarm set points, and other display data as well as drawing of process graphics as required. Software for report generation, system diagnostics and self-documentation shall be provided Vendor shall consider all the software functions available in system to ensure that all the features / deliverables are available in each operator station. Vendor shall provide detail list of software being offered with their license quantity in their offer. Each PLC based control system operator station shall have capability for accessing any graphics/ report related to any area of the plant.
Documentation Software Vendor shall provide documentation software that shall have a database which updates itself from the System Database so as to provide complete wiring details and I/O assignment details of all the PLC BASED CONTROL SYSTEM tags. It shall be possible to attach and view I/O sheets to any I/O tag name with this software. Cross-reference facility shall be available so as to search any tag name of the system. Page 30 of 93
Formatted: Font: Bold, Font color: Black
Import / export facility to MS excel, notepad, etc., shall be available in this software. Any change in tag name/range/description/channel assignment shall be automatically updated in this software. OPC Interface: Vendor shall provide license and software facility for OPC server (1no) and client (1no) along with necessary hardware required to make OPC interface functional. Loading of CPU and server shall be designed so as to accommodate OPC server for any future third party process optimisation on OPC interface.
Formatted: Font: Bold, Font color: Black
2.5 No.:
ENGINEERING/OPERATORING STATION WITH HMI , QTY. 1
Formatted: Font: 14 pt, Font color: Black Formatted: Font: 14 pt, Font color: Black Formatted: Font: 14 pt, Font color: Black
Engineering station shall be located in System room & not in local control panel. Engineering Station shall also have licensed facility of HMI for process control Engineering station make and model acceptable is only DELL make server grade PC-12th generation, RAID-5 Configuration. Server grade operating system -2012, RAM 8GB, HDD-500GB and dual redundant power supply with 24 LED monitor. Engineering station shall have all the features and capabilities of operator stationoperator station as mentioned above. In addition it shall also have other capabilities as mentioned below, a) Engineering Tools :Tools: i. The tools facilitate on-line and off-line Engineering functions of the system. ii. Engineering tools to build graphic and database shall be available on a standard environment viz. Windows operating system. iii. Graphics /Database tools shall comprise of easy use of GUI Icons / Menus b) Ooperator station shall be also licenced for engineering capabilities c) Auxiliary drive shall be available for system software loading and taking backups. d) Other specifications shall be same as for operator station. e) Engineering licence shall be available for all the tags. f) It shall be possible to all engineering functions online without shutdown / downloading of any controller or station.
Formatted: Font: Bold, Underline, Font color: Black
2.6
OPERATOR STATION UPDATE TIME

Page 31 of 93
Formatted: Font: 14 pt, Font color: Black Formatted: Font: 14 pt, Font color: Black
System shall guarantee the following update times : a) b) c) shall d) Display page call up time: Less than 1 sec for non graphic pages. Graphic page call up time: Less than 1 sec for a page with less than 50 live points. Page refresh time: Live points in the actually displayeddisplayed page be refreshed every second (50 live points approx.) Issue of commands: less than 2 sec from station to field including feedback.
2.7
SYSTEM SECURITY
:
The following three levels of security shall be provided by the system a) Operator level b) Process engineer level c) Engineering level
The type of security at the Operator Station & Engineering station shall be password type. START menu & exit/+/- buttons of Station window shall be non operable & hidden from screen. Operator shall not be able to access any of Windows utilities whenever locked. The system shall be designed in a way that minimises the possibility of a hardware or software failure. Consequently, in the event of failure, effective diagnostics and error messages shall be provided to facilitate detection and resolution of the failure. The vendor based on his knowledge of his equipment, shall provide additional on-line diagnostics and checks in addition to those in the specification. In case of any mal-operation it should be possible to identify from which staion the operator action took place.
2.8.1
a) b)
Power Failure / Auto Restart
When power is restored after power failure, the CONTROL SYSTEM shall reboot automatically The stations, controllers and process interface units shall have Page 32 of 93
c)
power-fail detection. Upon power failure, the hardware/software shall perform the necessary functions to bring the appropriate equipment to an orderly shutdown, including an orderly deactivation of all the processing. When data acquisition units and controllers lose power, it shall annunciate on CONTROL SYSTEM and logged along with the time of occurrence.
2.8.2
Memory Protection
The system shall be protected from being overwritten. The system software shall also be capable of protecting itself to ensure integrity. The memories shall have parity check and detection.
2.8.3
File and Data Security
All data communications shall have adequate error checking, detecting, reporting and recovery features. The failure of data highway shall be displayed on the alarm summary display at the station and also logged on printers.
2.8.4
Process Input-Output Checks
Every sampled analog value shall be checked against pre-set and low sensor reasonability limits. If a limit is detected, it shall be flagged and alarmed and appropriate quality coding indication is provided as part of the database. It shall be possible to disable the actual alarm condition knowingly. The system shall provide automatic open circuit detection of the thermocouple open circuit conditions. Open circuit detection shall not affect the accuracy of a temperature more than 0.25C. There shall be check on the analog signal input to the range of the analog to digital converter. determine if it is within
For alarm purposes, it shall be possible to define burn out up-scale or downscale values.
2.9
DATA BASE MANAGEMENT AND DATA BASE
The plant historical database shall be designed to store at least one-month data of productions, consumption, critical variables on hourly basis, as well
Page 33 of 93
as other standard data elements. It shall be possible to retrieve the data in the form of reports / files as defined by the user. Sufficient integrity features shall be provided to protect the data-base from catastrophic failures and corruption. The supplier shall provide facility for archiving of the operational data-base. The archive shall be such as to provide a backup of historical data on a continuous basis for very long periods. The vendor shall make available the structure and organisation of database to the purchaser. The database shall be global and provide logical independence from the physical configuration. The vendor shall provide a full and comprehensive database operations procedure for backups, reports generation, graphics operation, dataprotection, securities etc.
2.10
ON-LINE HELP
Formatted: Font: 14 pt, Font color: Black Formatted: Font: 14 pt, No underline, Font color: Black
An on-line help facility shall be provided at the console, which shall provide the user information about the following: a) System configuration and details. b) Maintenance manuals/procedures. c) Software and software features. d) Process manual including P&I diagrams. System shall have its own documentation so that engineers may not carry manuals to rectify the fault.
Page 34 of 93
CHAPTER III CONFIGURATION AND TECHNICAL SPECIFICATIONS
Page 35 of 93
3. 3.1
CONFIGURATION AND TECHNICAL SPECIFICATIONS

OVERALL CONFIGURATION
The configuration of the system shall be such as to provide a plant network with modules for Operator / Engineering Stations, Controllers, input/output, Historic database, etc. The main data highway shall provide peer to peer communication between the modules. All communication shall be dual redundant. The configuration schematic shall be furnished. Client-Server architecture is not acceptable. All three stations shall have direct access to PLC based control system controllers. In view of keeping low cost & at the same time ensuring high reliability, RCF has not asked for any SIL 3 /TUV certified/ TMR /Quadlog PLC. PLC cards shall be only provided in redundant configuration as specified in 2.1earlier. Even though, vendors can offer high end products as a standard feature ,any additional features regarding redundancy/safety which are not asked in NIT shall be responsibility of vendor in view of high cost. The PLC based control system shall be predominantly software driven where functionality and personality of the devices shall be definable at the logical level rather than through physical interconnection of the devices.
3.2
COMMUNICATION
Data Transmission Rate: Capable of high speed data transfers over redundant Ethernet in the range of 100 MB/sec. Ethernet shall have capabilities to detect & self-rectify faults for undeterred communication to various intermediate nodes on network. The system network shall have a Protocol & industry standard. The main highway shall be preferably MAP / IEEE 802.4 compliant. Communication between control system and operating station(2 nos) (located in remotely located control panel) shall be distributed among the distance of 50 meters. The communication should be redundant. Vendor shall quote suitable media & furnish requirements for laying Ethernet cable to have secured communication. Cost of cable laying/installation of infrastructure such as tray work etc. shall be in scope of vendor in view of expertise and one point responsibility.
Page 36 of 93
3.2.1 Internal Communications It shall be possible for the vendors standard communications networks to be fully redundant with automatic switch over. It shall be possible to monitor the status and active communication path at any time. Failure of one of the redundant cables shall not degrade system performance. Communications error checking techniques shall be incorporated so that the probability of an undetected single bit error occurring is one in 100 million. Communications system configured as redundant shall either use the backup path continuously or check the backup path at least once per minute to determine if it is operating normally. ETHERNET shall be extended on dual redundant Fibre optic cable up to a distance of 250 mtrs.(Total length for dual redundant cable shall be 500 mtrs.) Which shall have total 5 nodes for connection of operating/engineering stations & one remote DI/DO rack. Stations shall be connected to any of the nodes up to 250 mtrs. Lengths. Ethernet switch shall be placed in System marshalling cabinets located in Methylamine plant. Failure or planned shutdown of any one device connected to the communications network shall not affect the ability of the system to communicate with any other device on the network. 3.3
CONTROLLER SUB-SYSTEM:
The necessary hardware like I/O cards, processors, electronics etc. for the successful control of process shall be quoted as required for meeting specifications and achieving functionality mentioned in the NIT. The loading sheet indicating the distribution of controller and I/O cards for the specified I/O counts shall be furnished.
QUANTITY : AS REQUIRED FOR I/O COUNTS.
3.4
OPERATOR STATION(2 Nos.)/ENGINEERING STATION(1 No.)
Formatted: Font: 14 pt, Font color: Black Formatted: Font: 14 pt, Font color: Black
All Operator / Engineering station computers shall be DELL make workstation grade with latest configuration and with 24 LED monitor. Each 24LED console shall have its own individual station electronics i.e. each Page 37 of 93
LED station shall be a node on the main highway. a) b) c) d) Hi-resolution graphics/text monitors Mouse shall be provided as cursor pointing device. All console shall be with standard QUERTY keyboard. Each Keyboard shall have a set of dual function user configurable keys. These keys shall be configured to access important pages in single key stroke. Set point/ Output tolerance check- If Set point of a controller and its output in manual mode is changed by 10% or more than its previous value system shall have facility to warn the operator and ask for confirmation for such change and shall be software configurable. Each operator / Engg. Station shall have an access to global data base. Operator shall not have the facility to exceed the predefined Set-point HI and set-point LO (tagwisetag wise). This security shall be available tagwisetag wise and shall be configurable. Any single point failure shall not stop the plant operation and offered system shall have true redundancy to overcome this. Furniture: Furniture required for operator station shall be included in the offer. It shall be of Pyrotech make and of best quality. Individual metallic cabinet per operator/engineering station with heat dissipation fans wthwith conveniently bigger space for CPU shall be available inside the enclosure.
e)
f) g)
h) i)
Station Failure Security Failure or disconnection of a station shall not affect the operation of any other device on the communication system. Main Electrical switch The main electrical power switch shall be provided. A receptacle with breaker shall be provided for maintenance work. Internal wiring Incoming and out going cable /wires to or from to or from the panel, or both, shall terminate at the terminals mounted in the panel. All internal wiring after terminals shall be completed by the PLC BASED CONTROL SYSTEM vendor. Grounding As a minimum, safety grounding and signal grounding shall be provided with a grounding strip. Wire identification Page 38 of 93 a
Wire identification shall be provided with the same numbering system as the PLC based control system. Spares Switch with fuse for power supply Terminals Miniature circuit breaker for each instrument Name plate with tag number : : : 20% 20% 20%
3.5
REPORTS AND PRINTERS
This section details the general requirements for system reporting functions and reporting printers. Report Package: a. The contractor shall provide utility packages of application programmes to generate report formats using a conversational, fill-in-the blank approach. b) Software programming shall not be required to generate reports. c) It shall be possible to use any variable in the system in a report. d) It shall be possible to activate report on the following bases: i. On demand (operator's request) ii. Shift, daily and monthly iii. Event driven e) f) g) It shall be possible for all reports to be displayed on a station screen as well as printed on a report printer. Reports to the same device are to be queued. It shall be possible to configure a User Defined report to accept manually entered data for specified fields.
Report Printers: Printers used for report generation shall be dedicated for printing reports only. Printer shall be B/W Network LaserJet printer of HP make. Vendor shall specify offered make & model. Alarm and Event Printer Printer shall be Colour Network LaserJet printer of HP make. Vendor shall specify offered make & model.
Page 39 of 93
3.6
Print out shall show as a minimum the date, description, date and time of occurrence, time of acknowledgment, time of return to normal. Event logging suchlogging such as operator actions. Printer shall be provided with cover and furniture for installation.
STORAGE DEVICES
a) USB hard disk of size 500 GB for data backup. b) RAID 5 configurationconfigurations Hard Disk: Storage capacity as required but not less than 320 GB . GB. If higher capacity is required same may be offered. c) DVD R/W drive: Required d) Main memory RAM : Not less than 2 GB . e) CPU : 32/64 bit
3.7
MISCELLANEOUS
Necessary cabinets, interconnecting cables between controllers, I/O modules, marshalingmarshalling racks, etc. to all their sub-systems, console mounts and furniture, etc. shall be provided by vendor as per specifications mentioned in the NIT. Inter connection cables :cables : a) b) c) cCables for analog I/O : 0.5 mm2 stranded tinned Power supply cable : 2.5mm2, 3 core solid conductors, PVC sheathed, Size of the conductor as required. Digital output cable : 1.5 mm2 stranded tinned copper, PVC Insulated, PVC sheathed.
3.8
SYSTEM INTEGRITY FEATURES
The system shall have inherent integrity to prevent damage to equipment or adverse effects on the process arising out of system or component failures. These features shall be explained in the offer. 3.9
CABINETS
General Requirements Page 40 of 93
The cabinets comprising of following shall be provided for the control system:a) Relay : Relays with base shall be individual pluggable type (Omron /Pheonix /Paramount /Paramountmake only) with minimum 2NO/2NC contacts of contact rating 5A, 110VDC and 5A, 230 VAC.
b) c)
Mounting of Controllers, I/O cards and other system components. Power distribution :to house switches, step down transformer for 24 VDC supplies and circuit breakers for electric power supply for PLC based control system and power supplies etc. d) Annunciator/pump operation panel: with Pump remote/local & start/stop buttons. Also provision of emergency plant trip button. All of the DI & Dos on this cabinet shall be connected to system through Remote I/O on Ethernet. Type and construction All cabinets shall be of M/s Pyrotech /M/s Rittal make only. Cabinet's framework shall be provided and standardised in accordance to the following: a) Dimensions/appearance and colour in accordance with system cabinets: Vendor to specify b) Frameworks: Self-standing type, min. 2.3 mm thick CRCA steel plates, with channel base c) Painting cycle :In accordance to Mfr. STD - Colours to be defined in P.O. d) Cables entry - From the bottom e) Cabinet access - From rear & from front with locked doors complete with keys. f) Copper grounding bars. As a minimum, safety grounding and signal grounding shall be provided with a grounding strip. g) Terminals-Weid Mueller / phoenix h) Cables fixing through cable glands of SS 304 material. i) Service power socket with 240 V 50 Hz 500 Watt and 110 V AC. j) Forced Ventilation from top of the cabinets is required for all the cabinets. k) Internal Light: Duplex fluorescent type complete with switch (on/off) 240 V, 50 Hz. l) Incoming and out going cables/wires from and to the cabinets shall terminate at terminals in the cabinets. All these internal wiring, termination and interconnection between cabinets, PLC BASED CONTROL SYSTEM cabinets and panels shall be executed by Vendor. m) Wire identification shall be provided with the same numbering system as the PLC based control system. n) Reference standard -CENELEC or equivalent Indian/ Internationally recognised std. valid in India. o) Cable ducts - Dedicated for power, IS signal and non-IS signals. Cable Page 41 of 93
Formatted: Indent: Left: 1.5 cm, No bullets or numbering, Tab stops: Not at 1.5 cm
p) q) r) s) 3.9.1
ducts shall be of plastic with cover (150 mm) sized to allow loading coefficient of 80%. Execution: IP 50 or better, these shall withstand environmental conditions specified elsewhere. Spare terminals : Min. 25% Spare switch with fuse for power supply : 20% Lifting eye bolts (4 Nos. per cabinet) required.
MARSHALING CABINET
Field cable termination marshalling cabinet shall be comprising of termination of external field wiring and the system cables for the PLC based control system. 3.9.2
POWER DISTRIBUTION CABINET
Purpose of such cabinet is to allow power distribution from UPS (115 V 50 Hz) to PLC based control system cabinets, aux. cabinets. Cabinet will be organised in standard modules such as 110 VAC UPS supplies,230 VAC utility suppies,24 VDC. Each module will allow the placing of 10 feeders each one consisting of 10 MCB. Each cabinet is rated for standard modules. MCB shall be double pole type. It shall be designed according to the following requirements. a) b) c) Type and construction shall be as per 3.10.2 A proper protecting cover shall be provided at the terminals Main isolating switches for each primary supply by others shall be provided. d) Miniature Circuit Breaker (MCB) for all equipment,toequipment, to PLC based control system, peripherals, the panels, etc. e) Rating and Set of trip of MCB shall be decided by the vendor withvendor with due consideration of max. load, inrush current and heat dispersion. f) 10 % spare MCB to be provided. g) A 110VAC to 230 VAC is to be provided for 230VAC application and in each cabinet 230VAC service socket with switch is to be provided. In PDC individual MCB to be provided for each cabinet 230 VAC power supply. h) Name plates showing tag number or equipment number for each MCB. i) 1 One Digital Ammeter with fuse and 4-20mA analog output, CT operated and One & 1 Digital Voltmeter with fuse and 4-20mA analog output and 1 Digital Frequency meter with fuse. j) and 4-20mA analog output. All these analog outputs shall be connected to the system as inputs. k)j) 1 Power on lamp indication Page 42 of 93
l)k) cooling fan m)l) Fuse rating shall be decided during detailed Engg. n)m) Incoming cables shall be terminated on dedicated bus bar from which individual circuit shall tap the power. No looping of any kind is permitted. Isolation for each circuit shall be through two pole MCB. o)n) Wiring by solid copper conductor cable with 1100v grade PVC insulation. Cable conductor sizes shall be as per feeder rating. p)o) Terminals shall be of PVC and type, Weid Mueller/phoenix make, DIN rail mounted. All open type terminals with phase barriers. Terminal sizes shall be as per current rating.
3.9.3
AUXILIARY CABINET
Prewired Solid state annunciator( Minilec make only) with 32 windows having LED lamps with pump start/stop/remote-local buttons shall be provided in standard auxiliary cabinet as per previous specifications for MOC & COLOR. Motor start/stop/remote/local buttons shall be well known make two position type switch. Emergency stop button shall be protected by plastic cover. There shall be provision of installing small instruments such as turbine speed monitor transmitter/3300 vibration monitor on top of the annunciator housing. Such instrument housing shall be protected by plastic cover to avoid entry of Hazardous gas. If required the vibration monitor 3300 will be installed in the cabinet and it will be communicated to the control system through RS232/RS485. This will be decided during detail engineering. However vendor has to consider one communication card for the vibration system interface with the control system. Auxillary cabinet shall be positively purged with Instrument Air to avoid any Gas entry. Minimum IP 55 protection is required. Vendor shall discuss with plant Instrumentation personnel before submitting offer to understand concept. There are total 10 Remote/local and Start/stop buttons on the cabinet. LED cluster type pushbuttons shall be provided wherever required. On screen annunciator is not acceptable. Details of Annunciator windows shall be provided during data handover to vendor. Vendor shall provide electric hooter (with adjustable sound & tone). Hooter shall be configured to give audible alarm whenever any process or system alarm, annunciation occurs. Configuration of audible alarm shall be responsibility of vendor. Requirement of any additional DI / DO shall be specified. Vendor shall provide push button for emergency plant tripping. Page 43 of 93
3.10
SYSTEM POWER SUPPLY AND EARTHING/SHIELDING DETAILS Power Supply
Formatted: Font: Not Bold, Font color: Black
3.10.1
The power supply for the entire system will be provided by the purchaser from an uninterrupted/stabilized power supply ofsupply of 115V 10% (50 Hz 3%)at) at one point as single phase supply with neutral connected to ground. Where other voltages are needed, for instance 24 V DC. etc., this must be generated by power supply units which will be with in the scope of supply of the system supply. These SMPS should be of Digitronics or Phoenix make only with diode O-ring unit. The manufacturer shall ensure complete redundancy (hot standby type)&)and distribution in power supply of different sub systems like I/O module / controller cabinetracks, 24LED monitor, other hardware units etc. Complete power supply distribution shall be through minimum 4 power supplies with capability to supply 40%of normal supply current.so that in the event of failure of one power supply other power supplies can keep power uninterrupted. Power shall be distributed amongst three phases of 110 VAC UPS. Also current drawn by each power supply shall be indicated. Whenever any power supply fails, the status of the same shall be updated on System Status Alarms summary with an audible alarm. All redundant power supplies shall be wired so as to be truly redundant and shall draw supply from separate sources. In case of failure of any one supply source the power to the system shall be available from the redundant source and the redundant power supply. Load shall be equally distributed on the redundant power supply distribution. Vendor shall provide a power distribution cabinet to which the purchaser shall supply the bulk power as mentioned above. The distribution cabinet shall also include an isolation transformer. All further distribution including cabling to each cabinet are included in the vendors scope of supply. It is desired that each card/ instrument (smallest consumer) be provided with a separate switch/fuse unit with a common MCB for each cabinet. This shall ensure that as far as possible fault in any of minor components shall be isolated at that level itself instead of affecting other connected boards. Vendor shall also include in their scope power supply and cabling for auxiliary devices like annunciators, printers plotters, Winchester drives etc. Total CUMULATIVE current load for solenoid valves shall be 1 A for 24 VDC & 1A for 110 VAC in the existing system. Vendor shall furnish following details related to power supply: Page 44 of 93
Formatted: Underline, Font color: Black Formatted: Underline, Font color: Black Formatted: Underline, Font color: Black
a) b) c) d) e)
Total power supply requirements (including .auxiliary devices, peripherals, etc.) in VA and KW. Recommended fuse rating and specification for the two feeders from UPS at the UPS end. Main circuit breaker specification at the PDB supplied by vendor. Total maximum. heat load of control system. Single line diagram for the power distribution panel.
3.10.2
Earthing/ Shielding Details
The vendor will design and provide earthing as per the "Protecting Earthing System" according to IEC rules and the "Reference Earthing System" required for functional purposes. The two systems will be completely independent. Common earthing system is not acceptable. Even when OEM does not have different system for earthing, PLC based control system supplier shall have to opt for dual earth pit concept. There shall be no common point even at the "Main Earthing Terminal" which is connected to an earth electrode. Shielding of signal cables shall be within scope of the vendor. Copper strip/bar of suitable thickness shall be used as earthing strip. Vendor shall shall Design ,supplyDesign, supply of material, digging of pit, provision of earthmover to dig, layinglaying of earthing cables and installation of the earthing system shall be responsibility of the vendor. The earthing specifications and details shall be supplied by the vendor.
3.11 SIGNAL TRANSMISSION AND GALVANIC ISOLATION System shall cater to Hazardous area classification of Zone 2, Group II C, T4. Barriers shall be provided to meet this requirement as per IO details given in section 2.3.5 .2.3.5. 3.11.1
Isolation
The system I/O cards shall have built-in galvanic / opto-isolation feature for all the signals to be interfaced with the field instrumentation. Isolation shall also be provided between each of the channels in the I/O cards. Each node on the system shall also be isolated from the effects of any malfunction. The system shall also be protected from external high voltage disturbances and lightning, etc. 3.11.2
Grounding
Page 45 of 93
All the grounding requirements shall be in the scope of the vendor. Vendor shall submit grounding scheme for power ground, signal ground and system ground. a) b) c) AC safety ground and instrumentation circuit ground shall conform to NEC, Article 250. The AC safety Ground bus shall be directly bolted to the cabinet without the use of insulators. A 35 mm 2 screw type compression connector shall be provided on either end of each ground bar for interconnecting with other ground buses or to the Instrument System Ground Node (ISGN). Ground buses inside termination cabinets shall be made of solid copper measuring normally x 1 in, suitably drilled and tapped for screw terminals and wire lugs, or fitted with screw type compression lugs. The ground bus bars shall be labelled as follows: I.AC SAFETY GROUND for all exposed metal surface of cabinets, racks, chasischassis GND connections, etc. Individual wiring interconnections shall be minimum 1.5 mm 2 copper wire, green or green with yellow tracer or green with yellow tracer insulation. II.SHIELD CONNECTION for connecting cable and wire shields Interconnections between shield consolidation points and the bus bar shall be minimum 1.5 mm 2 copper wire, green or green with yellow tracer insulation. III.DC REFERENCE GROUND(i.e. for all DC analog / digital commons). Interconnections between DC common consolidation points and the bus bar shall be minimum 1.0 mm 2 copper wire, insulation to be green or green with yellow tracer. 3.12 3.12.1
d)
e)
MAINTENANCE Maintenance tools and aids
The system shall provide suitable diagnostic procedures for trouble shooting. Any card failure / abnormality shall be indicated on the operator console as well as on the printout. The supplier CAN provide maintenance tools such as the following: a) b) c) d) e) f) g) Card extenders Special purpose cables Testing jigs for trouble-shooting all types of cards Diagnostic software Diagnostic software instruction manual Any other tools/instruments required for diagnostics Adequate maintenance / service manuals, including circuit diagrams, trouble-shooting procedures, test point/signatures etc. Page 46 of 93
H)h) Anti staticAnti-static gloves 3.12.2
Maintainability
The system shall be modular and shall be easily maintainable. The variety and number of cards shall be at minimum. It should be possible to change the cards on-line without the need to poweroff the card and without affecting the functioning of the system. 3.13 3.13.1
SYSTEM ENVIRONMENTAL CONDITIONS Control Room
The PLC based control system cabinets will be installed in a 12 X 12 size room located adjacent to compressor house . The System layout shall be finalised with due consideration of plant operation, vendors recommendation and the space available. The system room & Control Room is provided with centralisedwith air conditioning. The system shall be designed to work in the existing environmental conditions as listed below :below: Area classification FOR FIELD AREA :AREA : Class Zone 2 Gr. II C, T4 Temperature : 10 to 40 C Relative Humidity : 40% to 80% non% non-condensing
3.13.2
Ergonomics
The design of the entire system, including racks, monitors, keyboards, peripherals, colour scheme and layout shall be ergonomically sound and shall conform to ISA standard / NEMA standard. 3.14
RF INTERFERENCE
There shall not be any adverse effect in the system functioning due to R.F. interference from VHF transreceivertrans-receiver sets being used in the vicinity / factory premises. The vendor shall state the requirements such as distance ,distance, output power, frequency etc. of normal radio equipment (walkie-talkie) from control room instrumentation. 3.15
GENERAL GUIDELINES FOR HARDWARE/ENGG
All system cables shall be multi-stranded prefabricated with plug in connector secured well with clamps shall be provided.
Page 47 of 93
All terminals shall be of reputed make such as Weid Muler / Phoenix / connectwell. Wiring terminations shall be with lugs. All termination strips of field all field instruments shall have fuse of appropriate rating. All DO termination strips shall have blown fuse indicating LEDs. All power termination shall have Perspex cover to avoid accidental touches. Power supply system shall be designed in such a way that by removal of any unit other units functioning shall not be affected. 3.16
TEST AND INSPECTION BY THE VENDOR
Inspection of steelworks, finish, equipment, wiring, name plates and maintenance and functional testing of power distribution circuits, alarm circuits, and instrument loops, shall be as a minimum be performed by the vendor, prior to customers witnessed inspection. 3.17
CUSTOMERS WITNESSED INSPECTION
The vendor shall produce detailed test procedures for review prior to final acceptance test by purchaser. Any documentation for hardware and software shall be completed and available for the test, in addition to the purchasers reviewed test procedure.
3.18
FACTORY ACCEPTANCE TEST(FAT) OF PLC BASED CONTROL SYSTEM
In addition to the vendors standard test procedures, a factory acceptance test (FAT) shall be performed with the purchaser present at the vendors works. The FAT is intended to fully demonstrate that the PLC BASED CONTROL SYSTEM system have been made correctly andcorrectly and completely in accordance with all manufacturing, assembly and software configurations and that the system performance withperformance with the system specifications. The vendor shall provide standard FAT procedures and submit it to the purchaser for approval. The satisfactory completion of the FAT shall be a prerequisite to system shipment. The test shall include a) Mechanical built and finish quality b) equipment and subsystems inventory c) System recovery from short and long term power failures. d) Operation of all peripherals. e) Check on system redundancy, e.g. failure of cards and software alarm test. f) Complete functional check to demonstrate that the system operates in Page 48 of 93
g) h)
a manner as defined in this specification and relevant documents, based on all equipment of the system connected together, input/ outputs fully simulated. Configuration Test : Network configuration, Database configuration, Application software The vendor shall note that the grade of the FAT shall be in Ready for Operation once the FAT is completed.
3.19
ON-SITE ACCEPTANCE TEST (OSAT) OF PLC BASED CONTROL SYSTEM
The OSAT will be conducted after system installation on site and is intended to assure that no damage occurred to the system during shipment, that the system is correctly installed and that the system requirements are satisfied when connected to live field inputs/outputs. The Vendors engineer will attend this inspection at site.
3.20
INSTALLATION, TESTING & COMMISSIONING
Vendor shall offer the services of the installation team which shall carry out installation of equipment in the control room, laying the interconnecting cables inside control room, testing and commissioning of the system. All technical personnel deputed on site by vendor shall be fully conversant with the supplied system and offered software package. Vendor shall provide separate engineering station/ laptop along with separate license to his engineering personnel so that his activities related to PLC based control system system commissioning do not hamper the work of plant personnel. These shall be provided on temporary basis till installation & commissioning of PLC based control system is completed, after which the vendor may retrieve them.
Vendors responsibility at site shall include all activities necessary complete the job as per specifications including following: a) b) c) d) e) f) g)
to
Transportation /shifting of all cabinets/panels to system room. Opening of packings & sending of packings to scrap yard. Shifting of all cabinets/panels inside Methylamine control room as per the consent given by RCF. Installation of all PLC based control system equipment in syatem room. Laying/splicing/joining of Ethernet cable from system room to control room. Cabling of all power/ signal & system cables between different sub -systems. Safety /Electronic /Barrier (IS barriers make P&F) earthing of all panels Page 49 of 93
h) i) j) g) h) i) j) k) 3.21 a) b)
to earth pits. Mounting of all hardwire instruments in various cabinets. Mounting, wiring & termination of all free issue items given by RCF. Powering up the system, loading the system configuration carrying out internal loop checks for inter loop checks for inter-connection. Loop checking simulating with field instruments. Field tests Commissioning and on-line debugging of the system Performance of final acceptance test Submission of AS BUILT drawings.
LOOP CHECKING
Loop check shall be carried out by the vendor including checking interconnection configuration and over all system functioning. Loop checking shall be carried out to check the functional performance of all elements comprising the loop and thereby ensuring proper configuration, functioning and interconnection. All field instruments connected to control room shall be loop checked at 0%,25%,50% & 100% of FS (For both increasing and decreasing signals) Vendor shall co-ordinate for smooth & proper loop checking. Any discrepancy found during checking shall be brought to notice of RCF Engg.-in-charge. All loop checking shall be performed in his or his authorised representatives presence. All observations shall be recorded in suitable format and shall be submitted for approval.
c)
d)
Page 50 of 93
Chapter IV INFORMATION FROM PLC BASED CONTROL SYSTEM VENDOR
Page 51 of 93
4. INFORMATION FROM PLC BASED CONTROL SYSTEM VENDOR

VENDOR TO FILL UP FOLLOWING INFORMATION AND SUBMIT ALONG WITH THE QUOTATION :QUOTATION:
RCF REQUIREMENT
TO BE FILLED BY VENDOR. (VENDOR SHALL FURNISH DOCUMENTARY EVIDENCE TO SUPPORT PROVIDED INFORMATION)
VENDOR SHALL PROVIDE ALL/ ADDITIONAL DATA IN DETAIL AS MENTIONED IN FOLL. SECTION NO.
6.1
Formatted Table
1 GENERAL REQUIREMENT 1.01 VENDOR DISCLOSURE Vendor name: Model No.: Year of introduction of the offered system for commercial use: Any system introduced in the market after this model: No. of trained personnel available with vendor, experienced in installation, commissioning & operation of the system: Nos. of identical systems supplied in India Address of users & their phone, fax nos.: Vendor's organisational profile: Vendor's financial status: Capacity utilisation projection for coming one year: 1.02 VENDOR'S COMMITMENT No additional cost implication for any hardware & software additions by vendor of their own to the functional requirement without any change of scope by client. Page 52 of 93
YES / NO
Supply of spares for 15 years from the date of supply of system. Period (no of years) for which technical support shall be available to be mentioned. System should not become obsolete for 15 years. 2 SYSTEM ARCHITECTURE 2.01Architecture conforming to PLC based control system NIT. Vendor to indicate deviation & submit their architecture. 2.02 The communication shall be open as per OSI guidelines 2.03 Nos. of OSI layers supported by the system
YES / NO
1.3, 1.4, 1.5, 3.1
3.1, 3.2
3.1, 3.2
2.04 Proprietary hardware & software 2.05 System shall be open w.r.t. to compatibility& interchangeabilityinterchange ability at any period of time. Any old component can be replaced with upgraded one without any software change or hardware connection and slot modification. 2.06 Distributed database 2.07 Open operating system 2.08 SYSTEM HEALTH Automatic switch over from primary to secondary bus. Automatic retries in the event of errors. Dual power for Operator/Engg. station CPUs System level fault diagnosis. Status indication of all devices on the communication bus with history of errors. 2.9 CONTROLLER HEALTH Input over or under range. Computational check & error CPU bus time out. Watch dog timer error Page 53 of 93
YES / NO YES / NO YES / NO YES / NO YES / NO
2.1
Power supply status & error detection. Automatic change over from primary to secondary controller by automatic error detection. 3 DATABASE Single/multiple/distributed Database manager Database type Database name Database access 4 ETHERNET TCP/IP LAN FOR PROCESS CONTROL Details of Ethernet through Fibre optic communication details with maximum number of nodes 5 OPERATOR STATION 5.01 Quantity : 2 nos 5.02 CPU Make: DELL Model: Workstation grade Processors: Latest Chipset: Latest RAM Memory: 4GB Integrated / Add-in controllers: RAID controller for 5 Hard drives Drive Bays: Support for up to eight 3.5" SAS or SATA hot plug hard drives; Peripheral bay for tape drive plus one Combo CD-RW/DVD-ROM Hard drives: 3.5" high speed, not less than 250 GB, hot-plug hard drives Additional storage: Network interface card: Shall support redundancy Power supply: 110/230 VAC Hot-plug redundant power Operating systems: Latest Microsoft Windows As a optional item; for each operating station, Vendor shall provide CE 770 ATEN MAKE or equivalent USB KVM extender with deskew function. The automatic signal compensation and RS232 serial functionality allow acess to a computer system Page 54 of 93 2.9
1.3, 1.5.1, 3.2.1
2.4
from a remote USB console. Local & remote units connect at distances up to 300 mtrs. 5.03 MONITOR No of monitors: 2 nos total Screen size: 24 LED Make: Dell Model: Key board: Dell USB optical Mouse: Dell USB optical 5.04 Table Top Furniture: 2 nos 6 ENGINEERING + OPERATOR STATION 6.01 Quantity : 1No 6.02 CPU Make: DELL Model: Workstation grade Processors: Latest Chipset: Latest RAM Memory: 4GB Integrated / Add-in controllers: RAID controller for 5 Hard drives Drive Bays: Support for up to eight 3.5" SAS or SATA hot plug hard drives; Peripheral bay for tape drive plus one Combo CD-RW/DVD-ROM Hard drives: 3.5" high speed, not less than 250 GB, hot-plug hard drives Additional storage: Network interface card: Shall support redundancy Power supply: 110/230 VAC Hot-plug redundant power Operating systems: Latest Microsoft Windows 6.03 MONITOR No of monitors: 1 No. Screen size: 24 LED Make: Dell Model: Key board: Dell USB optical Mouse: Dell USB optical Page 55 of 93 2.5
Formatted Table
6.04 Table Top Furniture 2 Nos. 7 PRINTERSS 7.01EVENTS & ALARMS PRINTER Make : Hewlett Packard Model: B&W Printer Type : Laserjet Printer table Spare Cartridge 7.02 REPORT & TREND PRINTER Make : Hewlett Packard Model: Colour Printer Type : Laserjet Printer table Spare Cartridge set 8 SOFTWARE & HMI 2.4.9, 5.2, 5.8.2, 5.8.3 2.4.3, 2.4.5, 3.5
8.01 SOFTWARE 1) STANDARD FEATURES a) Operating system b) Display Developer c) Alarm Management d) Report Management e) System Diagnostics f) Engineering station functionality g) Self documentation h) Other software offered by vendor i) Loop built up facility j) Graphic built up facility k) Network configuration facility l) On-line addition deletion m) History report of maintenance n) Logging report of load/save facility o) Historical documentation o/p p) Monitoring of system operational status q) Software revision management Page 56 of 93
r) Detailed diagnosis of fault cause. s) System start up support t) Database backup/recovery facility u) Hard disk back up to & from systeamsystem database facility 2) APPLICATION SOFTWARE including complex loop software 3) OPTION ADDITIONAL SOFTWARE : System dDocumentation software 1 No. OPC server and Client software 4) Details of all licences required for operator station/engineering station/trends/historisation/all tags/displays/reporting etc shall be furnished in offer 8.02 STANDARDISED SCREEN DISPLAY AVAILABLE IN THE SYSTEM PER STATION Overview display Nos of pages ) areas for overview Nos. of plant groups/area Nos. of loops/area Display of process status on overview Display of critical/non critical alarms trips differentiation on overview Alarm per point Screen area in overview display in lines/column Memory space allocated for overview display 2.4, 2.5 2.4.9 2.4.9
8.03 GROUP DISPLAY Nos. of group/page. Total nos. of pages available for group display Group display shall contain bar graph display of individual loops, their digitalvaluesdigital values & status display. Auto/manual/remote selection for any loopsorloops or all loops shall be possible from group display. Set-point & alarm adjustment of any loop possible from any display. Page 57 of 93
2.4, 2.5
8.04 GRAPHICS DISPLAY Time for graphics display Interactive graphic No. of dynamic variables on each page Scrolling/rolling facility in any direction Continuous in both axis/or limited scrolling Nos. pages/group with rolling display Digital display/bar display/curves/key fieldcontrol fields/notes facility from graphic pages Full scale display of any partial display from any screen. Max. symbols available from symbol set. Nos. of symbols /system ISA symbols & primitives Graphic build up from operator console/ENGG station. Memory available for graphics Multi window facility for graphic &pop up window Dynamic change in graphic Alarm display on current viewing page. Single key operation to go to affected graphic page.
2.4, 2.5
8.05 HISTORICAL AND REAL TIME CURVE DISPLAY No. of recording points or curvesassignablecurves assignable at a time per system Facility of cursor or marker on the curvetocurve to pinpoint value at any pt. on the curve. No. of recording points or curvesassignablecurves assignable per system No. of recording points or curvesassignablecurves assignable per OPERATING system CONSOLE No. of TREND BLOCKS per system PER SCAN RATE No. of TREND BLOCKS per CONSOLE FOR ALL SCAN RATES No. of TREND GROUPS per system PER SCAN RATE No. of TREND GROUPS per CONSOLE FOR ALL SCAN RATES Page 58 of 93
2.4, 2.5
8.06 REAL TIME TREND No. of recording points or curves assignable at a time per system. Max. no. of curve field or graphs per screen display. and per Main memory resident programs or disk resident Capacity in MB trending 8.07 MESSAGE DISPLAY Alarm message display Nos. of alarms per page. Nos. of latest alarms on graphic page. Max. nos. of alarms store on system. 8.08 OPERATOR'S GUIDE MESSAGE DISPLAY Nos. of messages per display Total nos. of messages stored. Message length Memory allocation for messages 8.09 REPORTING & LOGGING Free memory space available for user defined report & logging formats Facility of automatic printout at userdefineduser defined report & logging formats Facility for automatic printout at userdefineduser defined time intervals Post trip event logging Facility of printout at any timemanuallytime manually as desired by user. Calculated variables for totals, minimum& averages. 9 AUXILIARY CONSOLE
2.4, 2.5
2.4, 2.5
2.4, 2.5
3.5, 2.4.5, 2.4.6
1.3, 3.9.3, 7.9, 2.3.5

Formatted Table
Size, Thickness of sheet Self illuminatingSelf-illuminating push buttons for pump start/stop & Remote/local 10 CONTROLLER SUBSYSTEM 10.01 CONTROL PROCESSOR & I/O PROCESSOR Page 59 of 93 2.1, 3.3
Make, Model Clock speed Single/redundant 10.02 I/O SUB SYSTEM Nos. of analog 4-20 mA dc input card. Nos. of analog I/Os cards Nos. of Thermocouple Input cards Nos. of digital inputs Nos. of digital outputs Redundancy at I/O level 10.03 POWER SUPPLY Redundancy/single Field transmitter power supply 10.04 CONTROL SYSTEM SPEED Closed loop Open loop Digital I/Os 10.05 MAIN MEMORY Capacity in MB(RAM) 10.06 CONTROLLER CAPABILITIES Nos. I/Os handling capacity Algorithms, Complex loops Nos. of closed loop processing Nos. of open loop processing Note : CPU loading should not exceed 50% 10.07 CONTROLLER SOFTWARE FACILITY control Selection Dynamic compensation Computational Logic Alarm & analysis Sequential control 11 .01 CABINETS GENERAL SPECIFICATION 11.01 CABINET GENERAL SPECIFICATION Page 60 of 93 3.9
Formatted: Font: Not Bold
3.1
Size Painting Fabricated from cold rolled steel sheet Cabinet drawing to be attached with offer Nos. of cabinets Front & rear opening Ventilation fan Panel illumination Terminals MAKE Type of cabinet 11.02 NOS. OF CABINET OFFERED a) System cabinet b) Power distribution cabinet c) Relay cabinet 12) CALCULATION & SIZING DETAILS WITH OFFER .
Formatted Table
Formatted: Font: Bold
Controller CPU loading Power consumption Bus loading Heat dissipation rate by system (for A/C system sizing). 13) ON-LINE HELP System configuration details Maint. manuals /procedures Software and its features Process manual including P&I Diagram DELL server grade machine PRINTER 2.10.
Formatted Table
Formatted: Font: Bold
Formatted Table
1.00
1.01
GENERAL REQUIREMENT
VENDOR DISCLOSURE Vendor name: Model No.: Year of introduction of the offered system for commercial: Any system introduced in the market after
this model.
Page 61 of 93
Nos. of trained personnel available with vendor, experienced in installation, commissioning & operation of the system.: Nos. of identical system supplied in India or Address of users & their phone, fax nos.: Vendor's organisational profile.: Vendor's financial status.: Capacity utilisation projection for coming 1.02 VENDOR'S COMMITMENT No additional cost implication for any software additions by vendor of their own to requirement with any change of scope by client. Supply of spares for 15 years from the date of supply of system. Period for which technical years should be available. System become obsolete for 15 years.
abroad.:
one year.:
hardware & the functional
support should not
2.00
2.01 2.02
SYSTEM ARCHITECTURE
Architecture conforming to DCS spec Vendor to indicate deviation & submit their architecture. The communication shall be open as per OSI guidelines
2.03 Nos. of OSI layers supported by the system 2.04 Gateway for communication with Ethernet & other vendor's system at plant 2.05 Proprietary hardware & software 2.06 System shall be open w.r.t. to compatibility & interchangeability at any period of time any old component can be replaced with upgraded one without any software change or hardware conn. & slot modification. 2.07 Distributed database 2.08 Open operating system 2.09 SYSTEM SECURITY Automatic switch over from primary to secondary bus. Automatic retries in the event of errors. Dual power for Operator/engg./server station CPUs System level fault diagnosis. Status indication of all devices on the comm. bus with history of errors. 2.10 CONTROLLER SECURITY Input over or under range. Computational check & error CPU bus time out. Watch dog timer error Power supply status & error detection. Automatic change over from primary to Page 62 of 93
secondary controller detection. 2.11 SECURITY AT CONSOLE LEVEL Console electronics failure/error detection. Error detection & identification of each type of modules Security at operator/Engineer
3.00 SYSTEM SUPPORTING STANDARDS & CORRESPONDING INTERFACES.

3.01 Displays
4.00
DATABASE
Single/multiple/distributed Database manager Database type Database name Database access
5.00 6.00
6.01
Ethernet TCP/IP LAN FOR PROCESS CONTROL

Fibre optic communication details
ETHERNET through
OPERATING STATION
STAION/SERVER Makes : DELL Model: Power-edge 2900 server grade 6.02 MONITOR No of monitor Screen size Resolution in Pixels Colour Display access time Key board Make: Dell 6.03 CONSOLE ELECTRONICS SUPPORT 6.03.01 SINGLE VDU/Console Electronics 4-20 mA o/p Voice o/p 6.03.02 MAIN CPU MEMORY Capacity in MB(RAM) 6.03.03 AUX. MEMORY Hard disc capacity
: 24 LCD
7.00
7.01
PRINTER AND KEY BOARD

EVENT OPERATOR LOG & ALARMS PRINTER COVER Make : HP Model: Page 63 of 93
Colour/B&W Type Laserjet Printing speed Printer table with drawer 7.02 REPORT GENERATION & TREND PRINTER WITH COVER Make Hewlett -Packard Model Color/B&R Type (Laserjet ) Printing speed Printer table with drawer 7.03 KEYBOARD Alphanumeric QWERTY keyboard Assignable keys 8.00 SOFTWARE FACILITY FOR OPERATOR CONSOLE 8.01 System I/O handling capacity HARDWARE CLOSELOOP OPENLOOP ANALOG 4-20MA T/C OTHERS DIGITAL INPUTS DIGITAL OUTPUTS SCAN RATES 8.02 Software 1) Standard a) Operating system b) Display builder c) Alarm advert management d) Report Management e) System Diagnostics f) Engineering station functionality g) Self documentation h) Other software offered by vendor 2) APPLICATION SOFTWARE including complex loop software 3) OPTIONAL SOFTWARE a) ERP for energy consumption calculation and maint Cost/operation cost calculation (preferably SAP) b) Self tuning 8.03 STANDARDISED SCREEN DISPLAY AVAILABLE IN THE SYSTEM PER STATION Overview display Nos of pages ) areas for overview Nos. of plant groups/area Nos. of loops/area Display of process status on overview Page 64 of 93
Display of critical/non critical alarms trips differentiation on overview Alarm per point Screen area in overview display in lines/column Memory space allocated for overview display 8.04 GROUP DISPLAY Nos. of group/page. Total nos. of pages available for group display Selection of group display through touch screen or light pen keying in Sequence of group display can be same as overview or can be rearranged Group display shall contain bar graph display of individual loops, their digital values & status display. Auto/manual/remote selection for any loops or all loops shall be possible from group display. Set-point & alarm adjustment of any loop possible from any display. 8.05 GRAPHICS DISPLAY Time for graphics display Interactive graphic No. of dynamic variables on each page Scrolling/rolling facility in any direction Continuous in both axis/or limited scrolling Nos. pages/group with rolling display Digital display/bar display/curves/key field control fields/notes facility from graphic pages Full scale display of any partial display from any screen. Max. symbols available from symbol set. Nos. of symbols /system ISA symbols & primitives Graphic build up from operator console /ENGG station. Memory available for graphics Multi window facility for graphic pop up window Dynamic change in graphic Alarm display on current viewing page. Single key operation to go to affected graphic page. 8.06 HISTORICAL AND REAL TIME CURVE DISPLAY No. of recording points or curves assignable at a time per system Facility of cursor or marker on the curve Page 65 of 93
to pinpoint value at any pt. on the curve. No. of recording points or curves assignable per system No. of recording points or curves assignable per OPERATING system CONSOLE No. of TREND BLOCKS per system PER SCAN RATE No. of TREND BLOCKS per CONSOLE FOR ALL SCAN RATES No. of TREND GROUPS per system PER SCAN RATE No. of TREND GROUPS per CONSOLE FOR ALL SCAN RATES 8.07 REAL TIME TREND No. of recording points or curves assignable at a time per system. Max. no. of curve field or graphs per screen display. Main memory resident programs or disk resident Capacity in MB trending 8.08 MESSAGE DISPLAY Alarm message display Nos. of alarms per page. Nos. of latest alarms on graphic page. Max. nos. of alarms store on system. 8.09 OPERATOR'S GUIDE MESSAGE DISPLAY Nos. of messages per display Total nos. of messages stored. Message length Memory allocation for messages 8.10 REPORTING & LOGGING Free memory space available for user defined report & logging formats Facility of automatic printout at user defined report & logging formats Facility for automatic printout at user defined time intervals Post trip event logging Facility of printout at any time manually as desired by user. Calculated variables for totals, minimum & averages. 9.00 ENGINEERING STATION: Shall be Server Grade DELL POWEREDGE 2900 or its advanced version with 24 LCD monitor or better 9.01 MONITOR Nos. of monitor Screen size Resolution in pixels(1280x1024) colors 256/more Display access time Touch screen/light pen Trackball/mouse Antiglare screen 9.02 STATION MAKE HP/DELL Page 66 of 93
9.03
9.04
9.05
9.06
9.07
10.00
11.00 11.01
11.02
Model CONSOLE ELECTRONICS SUPPORTS SINGLE VDU per Console Electronics Group of two Voice o/p Redundancy MAIN MEMORY Capacity in MB(RAM) Capacity in MB(ROM) Vendor to specify Capacity in MB(RAM) for user. AUX. MEMORY Hard disc capacity Streaming tape drive/digital audio tape / CD R/W CONTROL PROCESSOR Make: 32/64 BIT: CLOCK SPEED: Single/Redundant: SOFTWARE FACILITY Loop built up facility Graphic built up facility Network configuration facility On-line addition deletion History report of maintenance Logging report of load/save facility Historical documentation o/p Monitoring of system operational status Software revision management Detailed diagnosis of fault cause. System start up support Database backup/recovery facility Hard disk back up to & from facility from hard disk or streamer tape Electronic documentation AUXILIARY CONSOLE Size , Thickness of sheet Self illuminating push buttons for pump start/stop CONTROLLER SUBSYSTEM CONTROL PROCESSOR & I/O PROCESSOR Make, Model 32/64 bit Clock speed Single/redundant I/O SUB SYSTEM Nos. of analog 4-20 mA dc input card. Nos. of analog I/Os cards Nos. of Thermocouple Input cards Nos. of digital inputs Page 67 of 93
Nos. of digital outputs Redundancy at I/O level 11.03 POWER SUPPLY Redundancy/single Field transmitter power supply 11.04 CONTROL SYSTEM SPEED Closed loop Open loop Digital I/Os 11.05 MAIN MEMORY Capacity in MB(RAM) 11.06 CONTROLLER CAPABILITIES Nos. I/Os handling capacity Algorithms, Complex loops Nos. of closed loop processing Nos. of open loop processing Note : CPU loading should not exceed 50% 11.07 CONTROLLER SOFTWARE FACILITY control Selection Dynamic compensation Computational Logic Alarm & analysis Sequential control 12.00 RITTAL MAKE CABINETS 12.01 CABINET GENERAL SPECIFICATION Size Painting Fabricated from cold rolled steel sheet Cabinet dwg to be attached with offer Nos. of cabinets Front & rear opening Ventilation fan Panel illumination Terminals MAKE Type of cabinet 12.02 NOS. OF CABINET OFFERED a) System cabinet b) Power distribution cabinet c) Relay cabinet 13.00 CALCULATED & SIZING DETAILS WITH OFFER. Controller CPU loading Power consumption Bus loading Heat dissipation rate by system (for A/C system sizing). 14.00 ON-LINE HELP Page 68 of 93
System configuration details Maint. manuals /procedures Software and its features Process manual including P&I Diagram DELL server grade machine PRINTER
Page 69 of 93
CHAPTER V SCOPE OF SUPPLY & SUPPORT SERVICES FOR PLC BASED CONTROL SYSTEM
Page 70 of 93
5. SCOPE OF SUPPLY AND SUPPORT SERVICES:

5.1 5.1.1
SCOPE OF WORK: General
The present supply shall include a) System configuration & application software for all equipment part of present supply. b) System standard documentation (manuals) both hardware and software in 6 sets c) Project documentation intended as documents specifically produced for the present project in 6 sets. d) Control room engineering documentation necessary for inter-wiring of all cabinets or devices part of present supply. e) System full functional test in factory. f) Quote for spare parts for 3 years of operation g) Training courses as decided elsewhere in this NIT. h) Maintenance contract i) Start up assistance. j) Grounding system k) Interconnecting cables under the scope of PLC BASED CONTROL SYSTEM , special cables and their terminations. l) Laying of ETHERNET cable by dual redundant fibre optic cable for remote i/o(DI/DO rack ) & operating/ENGINEERING Station. m) All installation, functional checking, commissioning activities in the control room. This shall include the replacement of defective units. nm) Any other hardware / software necessary to make system complete and functionally operative. on) Overall loop checking between control room and field inst. o) Coordination and detailing of the communication between control system with main DCS and vibration system. Required assistance from the vibration system and DCS vendor will be provided.
5.1.2
The supply shall exclude
a) All civil works b) All installation activities in field.
5.2
SCOPE OF HARDWARE AND SOFTWARE:

Page 71 of 93
The scope of order shall include the design, supply transportation, installation and commissioning of the hardware and software system as mentioned in Chapter 8 and defined in Chapter 1 to Chapter 4 as well as other related tools and services mentioned in this section. Not withstanding the specification given in the ITBNIT and related documents, the supply, installation and commissioning shall include all items and services required for completeness and satisfactory performance of the system. The scope of the vendor shall include, but not be limited to the following. 1) Supply of necessary hardware and software as mentioned in the functional aspects of the system, technical specifications including accessories such as cabinets, mounting arrangement, stands, table tops etc. wherever necessary. At least 20% spare capacity with hardware shall be built in the system to enable the user to configure the system for future requirements. Interconnecting cables, power supply cables, earthing strips wherever required in the system within and up to battery limits (control room & system room area except where specifically mentioned) shall be supplied and laid by the vendor. The vendor shall be responsible for transportation and storage of the system and any part thereof until acceptance of the system by the purchaser. Inspection at site along with purchaser after the receipt of the system shall be carried out by the vendor. Erection, commissioning and successful operation of the system up to the stage of acceptance.
2) 3)
4)
5) 6)
5.3
SUPPLY OF BOUGHT OUT ITEMS
The supply of bought out items shall be of standard make. The supplier shall take prior approval from RCF before deciding the make of bought out items. 5.4
DOCUMENTATION
The supplier shall submit documents and manuals, in English, which shall be comprehensive and provide sufficient information for efficient operation, maintenance and use of the system. This includes, but not be limited to, the following: A) To be supplied with Bid : Number of cabinets and drawings and weight Number of consoles with layout and dimensions Power consumption Sensibility to Radio Frequency Interference (RFI) (Walki-talkies and Page 72 of 93
control room equipment) Type of special cable, if any. Suppliers technical standard documentation for hardware and software products included in the offer. Time schedule for engineering, procurement and testing. List of final documentation with samples of the items which are not covered by first seven points mentioned above. Description of the function of each program. This shall include the logic configuration requirements and constraints and subprograms used, memory map and special characteristics. Input and output details of each program. Listing of assembled programs with label and symbol tables in assembler/compiler language.
B)
To be supplied after ordering :
Vendor shall officially inform Project team along with contact nos. A kick-off meeting between Vendor and RCF both, for PLC based control system will be set up in order to define final time schedule and documents to be supplied. In addition regular project meetings shall be performed. Vendor shall submit duly signed progress report on fortnightly basis. Dimensional drawings of all cabinets Layout of all cabinets with positions of components and drawings of termination references. Earthing drawings with termination references Configuration details in hierarchical fashion. Maintenance and service manual for the system, sub - systems and individual units up to component level. List of software and system flow chart. Documentation of all application software such as flow charts, symbol library, reports, generated messages, basic software, graphics etc. Flow of programs for the supervisory controls if any. Software manual for data-base management, process management, graphics, utilities, real-time operating system, process management software, languages etc. Concise ready reference manuals shall be provided for operations, maintenance and software. All the above documents shall be supplied in 6 sets. Apart from documents listed above, the vendor shall provide documents as listed in the Table 5.1.
5.2.5
SPARES: (As optional item)
Page 73 of 93
The vendor shall submit a list of recommended two-year spares along with prices for each item separately. The vendor shall provide a justification for the list of 2 year-spares quoted. The vendor shall also provide as a part of the scope of supply, necessary commissioning spares, if any, free of charge.
5.2.6
MAINTENANCE TOOLS AND AIDS:
The vendor shall include in the scope of supplies the maintenance tools and aids.
5.7
TRAINING
The training shall cover complete education of all aspects of the PLC based control system. The training program shall be divided to impart training to two different groups. a) b) System Engineers group Operation group
Training shall be imparted in India only (for two different groups): Option 1: At the regular training centre of the vendor (with charges) Option 2: At RCF training centre (with charges) The tentative details of these are shown below. a) System Engineers Group: This training shall be for 12 instrument personnels imparting in depth knowledge of the system for maintenance and system configuration/modification in future. The training shall be conducted at the principals work of the vendor for 5 days. Vendor has to conduct this training program in batches. Operation Group: This training shall be for 15 operation personnel imparting knowledge of complete operation of the PLC based control system The training shall be conducted at the principals work of the vendor for 3 days. Vendor has to conduct this training program in batches.
b)
5.8 5.8.1
SUPPORT SERVICES: Support Capability

Page 74 of 93
The supplier shall be capable of providing support services of a very high order. RCF shall have the right to check-up the supplier's support performance from independent sources. The supplier shall indicate the organisation, manpower and other resources of customer support division. The supplier shall produce documentary evidence of support from the principal for a period of 15 years. The address of the principal may also be mentioned. 5.8.2
Software And Documentation Updates
Any changes, revisions, de-bugging patches, etc. to the systems and application software shall be provided to RCF on a continuous basis as and when they are released/ developed by the vendor or the principal manufacturer. Also updates to documentation shall be provided. 5.8.3
Hardware/firmware updates
The vendor shall undertake to keep RCF informed about any development in the hardware/firmware versions. This shall be obligatory on the part of the vendor. Any developments arising out of shortcomings of the systems in the performing its designed task shall be carried out by the vendor at RCF's site in the form of regular engineering charge orders free of cost including hardware and deputation of vendor's engineer to site. The revisions brought out for enhancement of performance shall be made available to RCF. The supplier / principal shall have RCF on their mailing list for all software, hardware and firmware updates and developments. 5.8.4
Spares availability
The vendor shall ensure stocking of spares within the country and the same shall be made available on demand within a period of 24 hours. The supplier shall further ensure the availability of all spares for at least 15 years from the date of acceptance of the system. The supplier shall furnish a certificate to this effect from their principal. 5.8.5.
Personnel Support Services:
The vendor shall make available whenever necessary, the services of the specialists at RCF site within 24 hrs. from the time of communication, telephonic or otherwise. Page 75 of 93
5.8.6 1)
Deputation of vendor's engineer:
The supplier shall guarantee availability of one engineer at site (within 2 hours)during) during first two months of guarantee period free of charge start ing after the commissioning of the PLC BASED CONTROL SYSTEM of the plant. 2) The engineer posted shall be the one who is involved in executing the technical aspects of the system from the initial stage. The engineer shall assist the purchaser in maintenance and upkeep of the system including all necessary liaisons with the vendor offices and personnel. The resident engineer shall also impart on-the-job training to RCF's operation and maintenance staff.
5.8.7
AComprehensive Annual Maintenance Contract
The supplier shall furnish charges for maintenance of the entire PLC based control system on a yearly basis for a period of four 5 years post warranty in two options: I) The charges may shall be quoted on the basis of total maintenance ( including replacement of spares). II) The charges may be quoted on the basis of total maintenance (excluding replacement of spares). In this option vendor shall furnish the list of spares to be maintained by RCF for four years with unit price of the same. Theseis maintenance arrangements will be applicable post warranty for period of 54 (Five) years. During the warranty and AMC periods as per option I., critical spares shall be kept at RCF Chembur site. During the warranty period and AMC periods, problems in software such as bugs, etc. shall be patched at no extra charge. The AMC (both the options) shall include the following: a) Emergency calls b) Preventive maintenance c) Annual shutdown maintenance : : : 4 per Year. 2 Man-days per Half Year. 4 Man-days per Year.
Page 76 of 93
5.8
TABLE 5.1
DOCUMENT SCHEDULE
Vendor shall provide the following final documents in English. In case of certificates etc. which are not in English, Translation of the same shall accompany the certificates. All documents shall be A4 or A3 size only. These documents shall be supplied for PLC BASED CONTROL SYSTEM
Page 77 of 93
TABLE 5.1
P = PRINT Sr. No. Description With bid F= CD = CD ROM COPIES REQUIRED For Approval PRINTS COPIES REQUIRED Certified Final Prints COPIES REQUIRED Certified Final F/CD
1.
2.
3. 4. 5.
6. 7. 8.
9.
10.
11. 12.
13.
Sr.
Technical Catalogs, specs & data sheets System configuration Drawings Controller sizing details Bill of Material List of Spares for commissioning & 2 years spares Power consumption and heat load Deviation List Milestone charts with network schedule including a) Cabinets / Racks b) Base frames c) Other issues System Configuration Manuals System Operation & Maintenance Manuals Manuals for bought out items Power Distribution Diagram, GA & Internal layout Cabinet/ Console GA & Internal layout, Interconnection cable routing Description
1 1 1
2 2 2
4 4 1 1
1 1 1
4 1 4
1 1
COPIES Page 78 of 93
COPIES
COPIES
No.
With bid
14. 15. 16.
17.
18. 19.
20. 21. 22.
23. 24. 25.
26.
I/O Assignments I/O Rack loading diagram I/O Card Terminal Board Loading Diagrams Data communication bus and I/O communication bus interconnection Diagrams System grounding Diagrams Loop diagrams showing all terminal details Internal Wiring diagrams Interconnection Cable Schedule Network configuration& Definition Database Configuration Custom Graphics Software Schemes for Control /Interlock Logic FAT Procedure Note:
REQUIRED For Approval PRINTS 1 1 1
REQUIRED Certified Final Prints 4 4 4
REQUIRED Certified Final F/CD 2 2 2
1 1
4 4
2 2
2 2 2
4 4 4
2 2 2
2 4 4
4 4 4
2 2 2
CDs for above documentation - 2 sets
Page 79 of 93
CHAPTER VI PREQUALIFICATION CRITERIA AND PLC BASED CONTROL SYSTEM ACCEPTANCE CRITERIA
Page 80 of 93
6.1
PREQUALIFICATION CRITERIA FOR VENDORS
Formatted: Left, Tab stops: 1.27 cm, Left + 1.5 cm, Left + 3.81 cm, Left + 5.08 cm, Left + 6.35 cm, Left + 7.62 cm, Left + 8.89 cm, Left + 10.16 cm, Left + 11.43 cm, Left + 12.7 cm, Left + 13.97 cm, Left
The Vendor shall be pre-qualified based on following criteria (Vendors are required to submit the following information with documentary evidence along with the un-priced commercial bid for the prequalification of the tender) A. Corporate Record: a. Name, address, telephone & fax nos. email address b. History and structure of Organisation c. Name of Directors and Chief Executive / Partners along with addresses and contact nos. B. Financial Status: a. Annual Reports of company for the last 3 years including the year ending 31st March 2013 b. Solvency Certificate from bankers of minimum value of Rs.25 Lakhs c. Excise / Sales tax / VAT registration numbers (TIN No.) and PAN Nos. for Indian Vendors only. d. PF / ESIC Nos. if applicable for Indian Vendors only. C. Past Performance / Experience: i. Vendor shall be OEM (Original Equipment Manufacturer) ii. The vendor should have supplied at least one complete control systems for Turbo Compressor in fertilizers/petrochemical/refinery industry in India during the last five years and same shall be working satisfactory and trouble free. iii. Bidder shall submit the copy of Purchase order executed for such complete control system. iv. Bidder should also submit performance certificates from the buyers for the complete control system. v. The name of contact person of the buyer along with telephone no. and correspondence address should also be furnished. vi. Vendor shall support for the offered system for the next fifteen years. vii. The vendor should have sales and service support available in India. viii. The offer of only those bidders who has supplied complete control system for similar application will be considered as prequalified party.
Page 81 of 93
6.2
CONTROL SYSTEM ACCEPTANCE CRITERIA
RCF shall accept the PLC based control system before clearing SD/PBG only after successful & timely compliance of following criteria: a) The PLC based control system with all subsystems including hardware, software communication systems, auxiliaries have been supplied, installed and commissioned to the satisfaction of RCF. Training has been imparted to RCF's personnel as stipulated in section 5.7 All the documentation as given in section 5, table 5.1as well as those required for complete comprehension of the system has been delivered. All services as mentioned in section 5 are complied with by the vendor. All other activities, whether stipulated in this NIT or not, but which are necessary for meeting the requirements of PLC based control system have been completed by the vendor or by any sub-contractor of the vendor. In case the supplier uses 2 year spares stocked by the purchaser for commissioning of the system, the date of acceptance of the system shall be counted from the date these spares are returned by the supplier to the purchaser.
b)
c) d)
e)
Page 82 of 93
CHAPTER VII CONDITIONS AND REQUIREMENTS OF BIDDING
Page 83 of 93
CONDITIONS AND REQUIREMENTS OF BIDDING

7.1
LANGUAGE:
All correspondence and manuals/documents shall be in English language.
7.2
CORRESPONDENCE:
All correspondence from the supplier shall be forwarded in duplicate to: The Chief Materials Manager(P) Rashtriya Chemicals & Fertilizers Ltd., Chembur, Mumbai-400 074 (M.S.) Tel.: 022 2552 2748 Website: www.rcfltd.com No correspondence, unless asked for, shall be entertained relating to technical or commercial points after the bid closing date. Any such correspondence is liable to be treated as invalid. 7.3
PRE-BID VENDOR'S VISIT TO THE SITE
The vendor if required may visit R.C.F Chembur Mumbai, site and inspect the site and conditions before submission of bids. 7.4
ACKNOWLEDGMENT TO ITBNIT
Acknowledgment of Invitation to Bid is required by telex/cable/fax as soon as possible. The Bidder shall approach RCF for any clarification in writing, telex, cable/fax which shall however not relieve the bidder of any of the obligations stipulated in the ITBNIT. 7.5
DELIVERY TERMS AND PERIOD
The PLC based control system shall be dispatched by air/road after the system checkout tests at the Vendor's / principal's work. The installation of the new systems shall be done during the shutdown of the plant. Page 84 of 93
Erection activities shall commence before the shutdown for those part of the system or sub-systems for which shall not interfere with the existing system or operation of the plant. The supplier shall plan his erection activities so as to complete it in the shortest possible time. The installation of the new system shall in any case be done in a period not exceeding continuous 5 days. The vendor shall give a detailed network schedule and milestone chart for the supply, erection and commissioning of the system and status updates on weekly basis. The logical sequence of activities for installation of new system during shutdown shall be clearly indicated in the network. 7.6
WARRANTIES AND GUARANTEES
The supplier shall guarantee that all material, goods, spares and software supplied are of best design, material, components and workmanship and that the goods are new, of the latest manufacture and free from any defect. If any defect or bug is found in goods or software, and the defect is attributable to the supplier, then goods shall be supplemented, repaired or replaced by the supplier and all related expenses shall be borne by supplier. In the event of delay by the supplier, RCF shall reserve the right to rectify the same at risk of the supplier and the cost shall be back-charged to the supplier. The entire system shall be guaranteed for minimum period of 24 30 months from the date of supply or 2418 months from the date of installation whichever is earlier. In case of repair/replacement of any requirement or sub-system or part thereof during the warranty period, the replaced equipment or sub-system or part shall have a further warranty for a period of 24 months from the date of repair/replacement. All software shall be guaranteed against bugs for all times. Replacement of spares during the warranty period shall be free of charge. All the services provided under an AMC shall also be provided during the warranty period of 2 years. 7.7
PRICES
The vendor shall quote on all inclusive lump-sum value for the complete system. Detailed break-up of prices alongwith unit rates for each item/different items/services shall also be indicated to facilitate adjustment of lump-sum value in the event of changes made by the purchaser form ITBNIT specifications. Offers without itemwise break-up of prices are liable to be rejected. Page 85 of 93
Prices of optional items shall be indicated separately. Changes in lump-sum value shall be considered only in case of changes made by the Purchaser. The vendor is advised to check and ensure that all items are included in the offer and the lump-sum value quoted. In any case, it is deemed that the vendor has studied the ITBNIT documents in their entirety and no increase in lump-sum value shall be permissible, if the ITBNIT specifications remaining unchanged, vendor claims at a later date items are omitted on account of whatsoever reason. The offer shall be in Indian Rupees, however the extent of customs duty component shall be indicated. In case of a import content, the CIF value is to be indicated in foreign currency. Bids are liable to be rejected if the CIF value is not indicated. 7.8
PAYMENT TERMS
RCF's standard payment terms as given in the "Standard Terms and Conditions" shall prevail. 7.9
SUBMISSION OF BIDS
Bids shall be submitted in quadruplicate and shall be typewritten or printed. The bids shall be submitted in three separate parts as follows: a) Technical bid
This shall contain the detailed technical offer and specifications in accordance with the requirements and specifications given in ITBNIT. Deviations from the stipulated specifications shall be clearly indicated. Alternate specification/configurations, if any shall be indicated with explanatory notes on how these would comply with the functional requirements. The technical bid shall also contain a technical summary in the same sequence and number/sub-number of the sections included here in, the compliance and deviations from specifications and requirements in summary form. This shall be such as to have a one-to-one correspondence with the sections 1 to 5 of this ITBNIT and shall indicate the overview of entire offer. These bids without the technical abstract sheet as stipulated here are liable to be rejected at the sole discretion of the purchaser. In addition to the technical summary, the vendor shall also fill the technical abstract as given in Attachment Abstracts 1 to 3. There shall be two options for the technical offer, Option I:DCS only installed in Methylamine plant with Ethernet limited only in the area of Methylamine plant. All operating stations shall be with full Page 86 of 93
capacity & Annunciator/pump operating panel shall be connected to DCS fixed local I/Os(DI/DO). Option II: Spreadup of DCS shall be in the Methylamine plant control room. But as mentioned previously in , II. FUNCTIONAL REQUIREMENTS OF DCS: 2.3.5 III. CONFIGURATION AND TECHNICAL SPECIFICATIONS OF DCS : 3.2.1 IV. INFORMATION FROM DCS VENDOR:5 There shall be a provision of extended Ethernet on dual redundant Fibre Optic cable laid from Methylamine control room to Methanol control room. Distance between both control rooms is approx..250 Mtrs. There are cable racks available connecting both plants. Vendor shall lay Fibre optic cable on these racks. If separate dedicated cable racks are necessary for communications security then, vendor shall inform RCF to install such cable rack with specifications. RCF intends to have flexibility of putting operating/engineering stations in Methanol or Methylamine control room. There shall also be provision of one Annunciator and /pump operating panel (i.e auxillary console) connected through Remote DI/Dos on Ethernet which also can be placed anywhere in Methanol or Methylamine control room. RCF also intends to have facility of conversion of one of the operating/engineering station in to view station. No controls shall be possible from view station but it shall be used only to view process dynamic data. Printers shall also be connected to full capacity operating station, wherever it is placed. c) Unpriced Commercial Bid
This shall contain the Earnest Money Deposit and copies of the unpriced commercial bid, which shall be identical to priced commercial bid with prices left blank or duly blanked out. Following items shall be separately incorporated in standard commercial & unpriced commercial bid format given by purchase dept., - Price for Option I - Price for option II - Installation & commissioning - Training - Post warranty AMC for 54 years with yearly prices - Minimum 2 years required Spares cost d) Commercial bid with prices
This shall contain price details both lump sum and itemwise break-up including duties, taxes insurance, levies and other applicable to the order.
Page 87 of 93
The three parts of the bids as listed above shall be sealed in three separate envelopes each marked clearly on the cover the as to the content i.e. Technical, Unpriced Commercial, Priced Commercial etc. Bids which are not accompanied with Technical Summary and Technical and Commercial abstracts are liable to be rejected. The sealed envelopes should be properly identified with the ITBNIT and due date and brief description. Bid shall be submitted with all accompaniments and supplementary information and no documents having implications on price shall be entertained after the last date of receipt of bids. All bids shall be signed by the bidder's representative on each page of the bid, except for printed catalogues and brochures meant for general information. Bid will be opened in two stages: firstly the technical bids/unpriced commercial bids and subsequently the priced commercial bids. Factors other than price may form the criteria for evaluation of bids at the discretion of the purchaser. In the event of a bid being conditional or ambiguous, RCF shall reserve the right to reject the bid at their own discretion, without assigning any reason thereof.
7.10
LIQUIDATED DAMAGES
These shall be as per the standard terms and conditions of RCF. 7.11
OTHER TERMS AND CONDITIONS
Standard terms and conditions of the ITBNIT are enclosed in the two following documents:
a) Instructions to Bidders. b) General terms and conditions. All other terms and conditions which are not specifically stipulated in this document shall be as per the clauses in the 'Instructions to Bidders' and 'Standard Terms and Conditions'. Page 88 of 93
Page 89 of 93
CHAPTER VIII OVERVIEW OF SCOPE OF SUPPLY
Following Table lists briefly the generic items which are required in minimum for, but are not limited to, the scope of supply for Associated Gas Compressor plant PLC BASED CONTROL SYSTEM at RCF, Trombay. A HARDWARE ITEMS QTY OPERATING STATION DELL MAKE SERVER GRADE PC-12TH GENERATION, RAID-5 CONFIGURATION. SERVER GRADE OPERATING SYSTEM -2012, RAM 8GB, HDD-500GB AND DUAL REDUNDANT POWER SUPPLY WITH 24 LED MONITOR. OPTICAL 2 KEYBOARD & MOUSE, ETC. AS AN OPTIONAL ITEM; FOR EACH OPERATING STATION, VENDOR SHALL PROVIDE CE 770 ATEN MAKE OR EQUIVALENT USB KVM EXTENDER WITH DESKEW FUNCTION. THE Page 90 of 93 UNIT
Formatted Table
NO.
AUTOMATIC SIGNAL COMPENSATION AND RS232 SERIAL FUNCTIONALITY ALLOW ACESS TO A COMPUTER SYSTEM FROM A REMOTE USB CONSOLE. LOCAL & REMOTE UNITS CONNECT AT DISTANCES UP TO 300 MTRS. ENGINEERING CUM OPERATOR STATION DELL MAKE SERVER GRADE PC-12TH GENERATION, RAID5 CONFIGURATION. SERVER GRADE OPERATING SYSTEM -2012, RAM 8GB, HDD-500GB AND DUAL REDUNDANT POWER SUPPLY WITH 24 LED MONITOR OPTICAL KEYBOARD & MOUSE, ETC. LATEST HEWLETT PACKARD (HP) MAKE BLACK & WHITE ALARM & EVENT NETWORK LASERJET PRINTER LATEST HEWLETT PACKARD (HP) MAKE COLOUR REPORT & TREND NETWORK LASERJET PRINTER ANNUNCIATOR (32 POINTS MINILEC MAKE) AND THE SWTICHES FOR REMOTE/LOCAL START STOP WITH DESK AND ARRANGEMENT FOR INSTALLATION OF 3300 VIBRATION MONITORING SYSTEM FURNITURE FOR HOUSING OPERATOR/ ENGINEERING STATIONS, PYROTECH MAKE AND OF BEST QUALITY. INDIVIDUAL METALLIC CABINET PER OPERATOR/ENGINEERING STATION WITH HEAT DISSIPATION FANS WITH CONVENIENTLY BIGGER SPACE FOR CPU SHALL BE AVAILABLE INSIDE THE ENCLOSURE FURNITURE FOR HOUSING PRINTERS PYROTECH /RITTAL MAKE SYSTEM, MARSHALLING & BARRIER /RELAY CABINETS PLC BASED CONTROL SYSTEM CONTROLLER & FIREWALL CARDS, INPUT OUTPUT (I/O) CARDS, CONTROLLER & I/O CARD MOUNTING FILES, BARRIERS, CONVERTERS, RELAYS, TERMINATION PANELS/ ASSEMBLIES,TERMINAL STRIPS, BUS BARS FOR POWERN AND GROUNDING, POWER SUPPLYS AND HUBS/ ROUTERS/ SWITCHES. COMMUNICATION CARDS FOR DCS AND VIBRATION SYSTEM
NO.
NO.
NO.
NO. each
NO.
Formatted Table
7 8
2 VENDOR SPECIFIC
NO. NO.
VENDOR SPECIFIC
NO.
Page 91 of 93
10
ALL TYPES OF MARSHALLING, I/O TERMINATING, POWER, GROUNDING, INTERNAL COMMUNICATION, NETWORK COMMUNICATION CABLES PVC COATED GI CONDUITS WHEREVER REQUIRED. SPARES FOR TWO YEARS OF OPERATIONS CPU,POWER SUPPLY CARD, AI, AO,DI, DO CARD (OPTIONAL ) AS AN OPTIONAL ITEM; FOR EACH OPERATING STATION, VENDOR SHALL PROVIDE CE 770 ATEN MAKE OR EQUIVALENT USB KVM EXTENDER WITH DESKEW FUNCTION. THE AUTOMATIC SIGNAL COMPENSATION AND RS232 SERIAL FUNCTIONALITY ALLOW ACCESS TO A COMPUTER SYSTEM FROM A REMOTE USB CONSOLE. LOCAL & REMOTE UNITS CONNECT AT DISTANCES UP TO 300 MTRS. DCS WITH EXTENDED ETHERNET. LAYING OF FIBRE OPTIC CABLE FOR ETHERNET. PROVISION OF NODES ON ETHERNET IN METHYLAMINE & METHANOL CONTROL ROOM. PROVISION OF ANNUNCIATOR/PUMP OPERATION STATION THROUGH REMOTE I/OS(DI/DO). FACILITY TO CONVERT ON FULL CAPACITY OPERATING /ENGINEERING STATION TO VIEW STATION. SOFTWARE ITEMS LICENSE & SOFTWARE OF OPERATOR STATION PERFORMING PLANT MONITORING & CONTROL OPERATIONS, VIEWING & CONFIGURING HISTORY ASSIGNMENT, TRENDS, GROUP DISPLAYS, EVENTS AND TUNING PARAMETERS OF ALL TAGS AS WELL AS FOR STORING HISTORY & EVENTS DATABASE.
VENDOR SPECIFIC
MTR.
11
NO.EACH
12
NO
10
Optional offers
Formatted Table
0 B
QTY
UNIT
NO.
Page 92 of 93
LICENSE & SOFTWARE OF ENGINEERING CUM OPERATOR STATION FOR STORING HISTORY & EVENTS, SYSTEM, CONTROL AND PLANT DATABASE AND PERFORMING ALL ENGINEERING ACTIONS LIKE CONFIGURATION, DEVELOPMENT, DELETION OF ALL SYSTEM ENTITIES LIKE TAGS, LOGICS, NETWORK & NETWORK CONSTITUENTS, GRAPHICS, HISTORY SETTINGS, EVENT SETTINGS, SECURITY AND USER PERSONALITIES & PASSWORDS, BACKUPS & LOADING OF SYSTEM, CONTROL AND PLANT DATABASE ALONG WITH PERFORMING PLANT MONITORING & CONTROL OPERATIONS, VIEWING & CONFIGURING HISTORY ASSIGNMENT, TRENDS, GROUP DISPLAYS, EVENTS AND TUNING PARAMETERS OF ALL TAGS. LICENSE AND SOFTWARE OF LATEST MICROSOFT OFFICE SUITE LICENSE AND SOFTWARE OF LATEST NORTON / MACAFFE ANTIVIRUS LICENSE FOR OPC SERVER (FEATURES NECESSARY TO SUPPORT INDEPENDENT OPC SERVER FUNCTIONS SHALL BE AVAILABLE IN THE HARDWARE SUPPLIED)
NO.
3 4
3 3
NO. NO.
NO.
6 C 1
LICENCE SOFTWARE FOR HISTORY/REPORT ETC.
NO
Formatted Table
SERVICES PRICES FOR 54 YEARS AMC TO BE LINED UP AFTER END OF GAURANTEE PERIOD (AS PER 5.8.7 OF NIT) TRANSPORTATION OF PACKINGS,UNPACKING AT SITE,INSTALLATION & COMMISSIONING OF COMPLETE PLC BASED CONTROL SYSTEM AT CONTROL ROOM TRAINING CHARGES (AS PER 5.7 OF NIT) (BOTH INHOUSE AND AT VENDORS WORKS)
2 3
Note: The scope of supply necessary to meet the detailed technical requirements mentioned in section 2other sections of this NIT document shall prevail overall and shall be strictly complied with.
Page 93 of 93

PLC Details of Agc Plant

Загружено:

Сведения о документе

Исходное описание:

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

PLC Details of Agc Plant

Загружено:

Авторское право:

Доступные форматы

TECHNICAL SPECIFICATIONS FOR NOTICE INVITING TENDER FOR THE SUPPLY OF PLC BASED CONTROL SYSTEM FOR ASSOCIATED

GAS COMPRESSOR PLANT

RASHTRIYA CHEMICALS AND FERTILIZERS LTD., CHEMBUR, MAHUL ROAD MUMBAI-71

CHAPTER I GENERAL SYSTEM AND TECHNOLOGY REQUIREMENTS

OVERALL REQUIREMENTS- SYSTEMS AND TECHNOLOGY

WAY FOR Ethernet approx..50 Mtrs.

1.4 TECHNOLOGY AND OBSOLESCENCE

Formatted: Font: 14 pt, Font color: Black

Use of standard Procedures:

Field Proven Systems

Distributed / Open Architecture

Spare Capacity and Expansion Capability

Software Revision Levels

Third Party Equipment

OPEN ARCHITECTURE DESIGN

PROVENNESS OF THE SYSTEM

CHAPTER II FUNCTIONAL REQUIREMENTS OF PLC BASED CONTROL SYSTEM

2. FUNCTIONAL REQUIREMENTS OF PLC BASED CONTROL SYSTEM

Formatted: Font: 16 pt, No underline, Font color: Black

2.1 CONTROL FUNCTIONS

Formatted: Font: 14 pt, Font color: Black

2.2 ALARM FUNCTIONS

Formatted: Font: 14 pt, Font color: Black

2.3 INPUT-OUTPUT SYSTEM

Formatted: Font: 14 pt, Font color: Black

Formatted: Font: 14 pt, Font color: Black

2.3.2 Scan Time

Formatted: Font: 14 pt, Font color: Black

500 msec. or better 50 msec or better 1 Sec or better

2.3.4 I/O Cards

Formatted: Font: 14 pt, Font color: Black

2.4 OPERATOR STATION, QTY :QTY: 2 NOS.

Formatted: Font: 14 pt, Font color: Black

All real time clocks in the system shall be source.

The details of the above functions are listed below:

2.4.1 Monitoring / Controlling

Formatted: Font: 14 pt, Font color: Black

2.4.2 Trend Display

Formatted: Font: 14 pt, Font color: Black

2.4.3 Alarm Display

Formatted: Font: 14 pt, Font color: Black

2.4.4 Colour Dynamic Graphic Displays

Formatted: Font: 14 pt, Font color: Black

2.4.5 Event Logging

Formatted: Font: 14 pt, Font color: Black

2.4.6 Report Generation

Formatted: Font: 14 pt, Font color: Black

Formatted: Font: 14 pt, Font color: Black

Process Engineering Environment

Formatted: Font: 14 pt, Font color: Black

Formatted: Font: 14 pt, Font color: Black

Formatted: Font: Bold, Font color: Black

ENGINEERING/OPERATORING STATION WITH HMI , QTY. 1

OPERATOR STATION UPDATE TIME

Formatted: Font: 14 pt, Font color: Black

Power Failure / Auto Restart

Formatted: Font: 14 pt, Font color: Black

Formatted: Font: 14 pt, Font color: Black

File and Data Security

Formatted: Font: 14 pt, Font color: Black

Process Input-Output Checks

Formatted: Font: 14 pt, Font color: Black