Control system services

Capability Presentation

26 March 2014

Plant Automation Services - What We Do?

Solutions
Automatio n System Design Automation Commissioni ng Plant Operati on Process Control & Optimization Productio n Optimizati on

Design, Development, Testing and Commissioning of PLC, SCADA, DCS systems

Offerings

Large Program Management Product evaluation Vendor Independent Automation Services

Control and automation of Machines, equipments, Remote Monitoring and Diagnostics

Process Modeling, Soft Sensors

Historians

PIMS CMMS

Advanced control

MES

Real-time integration across the plant floor and plant floor to the enterprise systems Plant IT applications development, re-engineering, migration, support

26 March 2014

Control System Offerings

Control System Design Solution and system architecting Optioneering (Product fitment, evaluation) System specification Hardware design Software design Validation and Regulatory compliance SCADA Audit Migration consultancy Control System Development System configuration Panel design and drawing services Application development Recipe programming Third party interface development Supervision of installation & commissioning

PLC/ SCADA/ DCS/ Drives Instrumentation Engineering Electrical Engineering

Instrumentation scheme design Instrument portfolio management Instrument design documentation services Index and Datasheet Interface drawing Loop drawing Hookup drawing Drawing migration services SmartPlant Instrumentation configuration and implementation

Electrical Requirement analysis Electrical Audit Low voltage electrical engineering Power cable engineering Lighting, Grounding & Lightening engineering Emergency power supply engineering Drawing migration services SmartPlant Electrical configuration and implementation

26 March 2014

TCS Experience in Control System Integration

Over 500K person hrs engineering experience in Control system design, application development & commissioning Engineering experience in Energy & Utilities, Life Sciences, Chemical, Steel, Food & Beverages, Automotive domain Ongoing assignment with Siemens Building Technology USA for services in engineering drawing for Fire & Alarm system for high raised buildings Till now TCS has Engineered & commissioned various control systems for 200 small size (Up to 250 I/Os), 120 mid size (250 to 1000) & 30 large size (More than 1000 I/Os) process plants

Key Engagements Successfully managed a large asset management programs involving migration, engineering & commissioning of 300 plants in phases for 4 years, for UK based utility major. Control systems deployed were mix of of Rockwells SLC500, ControlLogix, and Siemens SIMATIC S7 Series.
Migration and Re-engineering Engineered & migrated 3 Nos of legacy control system to PCS7 Successfully migrated FIX32 (Delta-V 6.3.4) to iFIX (Delta-V 7.4.1) Graphics for Delta-V system of a Pharma major in US Successfully engineered & migrated 10 Nos of legacy PLC control system to SIMATIC S7-300 Helped Siemens E&A USA for migration of COROS to WinCC from offshore in 2 projects

26 March 2014

CSIA Certification
TCS is certified for CSIA (Control System Integrators Association) Level 1, the highest level of certification. TCS is the first Indian organization to be certified by CSIA for Level-1. The Certification Audit covered General Management, HR Processes, Project Management, Quality, Financial, Business Development Technical Management

26 March 2014

Control System: Competency stack

Control Systems (PLC/ DCS)
Siemens S5, S7, PCS 7, TI Series Rockwell SLC 500, PLC 5, ControlLogix, FlexLogix, GE Fanuc 90 30 Series, Versamax Mitsubishi QnS, AnS, FX series ABB Advant, SatCon Schneider Quantum Yokogawa CS series Honeywell Experion PKS, TPS, TDC 3000 Emerson DeltaV Foxboro - IA

SCADA/ HMI

GE Fanuc Cimplicity, Fix32, iFix Siemens WinCC, OP/MP/TP Technomatix - Factory Link Rockwell RsView32, RsView SE/ ME, PanelView Mitsubishi Beijers E - Series WonderWare Intouch Genesis Citect Honeywell PlantScape, GUS

Historians

Plant Networks

Oracle / MS SQL OSI PI Historian Rockwell RSSql Honeywell - PHD

ModBus / ProfiBus / FieldBus / CanBus / InterBus DeviceNet, Controlnet Ethernet

Instrumentation Drives
Siemens Micromaster, Midimaster Rockwell Powerflex, Ultra series Servoes, Kinetix Motion Mitsubishi A Series, E Series, J2S Series, E Series B & R Motion Controls

ISA Standard Specifications IEC, BS and ISO Standards AutoCAD, e-Plan SmartPlant - Instrumentation Low Voltage Electrical Specifications NEC, IEC, NEMA, BS and IS Standards AutoCAD, AutoCAD-E, e-Plan, 26 March 2014 SmartPlant Electrical

Electrical

150 + strong team

Resource skill set map

Technology Exposure (E1) Experience (E2) Expert (E3)

E1 Exposure
Has applied the technology to a case / live situation. Understands why something is done in a particular way and its relevance Can pass a quiz/test on theoretical and practical aspects of the concept Is not expected to work entirely without guidance from supervisor

DCS
Siemens PCS7 Yokogawa Honeywell Emerson-DeltaV Foxboro ABB Reliance 10 1 1 1 1 1 0 5 7 2 1 1 8 8 9 5 7 3 2 2 2 2 1 22 23 10 0 1 23 25 16 9 3 3 3 3 0 0 0 40 30 7 3 3 26 34 3 7

E2 - Experience Has more than a mere understanding of the

technology Has applied the technology across multiple situations Can leverage the knowledge to make changes in other parts of the system Able to independently solve a case / live situation applying the technology Does not need supervision to perform effectively

PLC
Siemens Rockwell GE Fanuc Mitsubishi Schneider

SCADA
RS View WinCC Wonderware GE

E3 Expertise Has undertaken several assignments / projects

related to the technology Is able to question the assumptions underlying the concept in a more practical sense In TCS, is approached whenever when a problem related to the competency arises. Is Centre of Excellence. Can be a mentor others to build capability in the technology
26 March 2014 7

Differentiator
Technology Independent Design Standardization & Modularization
Exploring newer ways of using standardization and modularization to drive project implementation efficiencies Standardization & Modularization reduce rework improve quality.

Use of tools to enhance productivity

Assets Leverage existing and Create New

Exploring the usage of tools in every activity, in order to enhance efficiency of delivery capture human knowledge into tool components.

Innovation

Reuse
To date there have been more than 6000 instances in over 120 projects where standard modules have been re-used.
Knowledge based techniques for optimizaton

Document, Maintain and Share best practices Offshoring

About 65% of the development work will be carried at offshore, forwarding the cost advantage

26 March 2014

Project profiles

26 March 2014

Case Study Chemical industry

Distributed Control Systems, Migration from MACO 8000 to Siemens PCS7
Client Hercules FiberVision: Fortune 1000 Chemical Manufacturer, based in US Up gradation from multi platform and multi SCADA to single standardized platform Standardization of control objects and phase plates Unified recipe management (40 different products in a single line) Capturing the requirements comprehensively and applying a standardized approach in all aspects (functionality, design, development, and technologies) led to business benefits both in the short-term and long-term. Standardization of control objects and phase plates Providing unified recipe management and facility to change recipes in minimal time Merging two different systems into one better screen management, easier use Adding new parameters to the recipe system (optimizing previously stand-alone loops based on product recipe) Line downtime reduction, by way of online recipe management Ability to more easily produce 40 different products on one line 4 times more data need to continue to train people to fully utilize it (but, it will be powerful) Lower costs allowed the project to include a dedicated data historian server and the ability to share process data with 3rd party applications
26 March 2014 10

Problem

Solution

Result

Case Study Pharmaceutical Industry

Migration for Delta-V System
Client Leading pharmaceutical industry, based in US This project was part of migration strategy decided by client Graphics screen were to be migrated from Fix32 to iFIX No ready tool in Delta V is available for migration. Screen volume was very large, Migration time frame available was very short & Production loss was allowed. Design specifications were not available for existing process cells. Core Onsite & large offshore team was formed to take care of Time frame Issue. Screen migration was carried out on iFix V2.6 instead of New Delta V system & then these screens were integrated into Delta V 6.3.4 Separate teams were formed at offshore for Documentation, Graphics design, Quality Testing All the Design Specifications, System test scripts & traceability matrix documentation was generated at offshore & Actual system validation was done onsite. Approval of all the validation documentations was done in single cycle. Migration of 175 complex graphics along with documentation was done in record time of 2.5 Months. Control system migration was seamless & without any production loss.
26 March 2014 11

Problem

Solution

Result

Case Study: UK based Utility industry

Control system integration and upgradation
Client United Utilities: UK based utility company Control system integration of over 300 Water and Wastewater treatment plants and pumping stations Program schedule depends on Regulatory deadline. All have deadlines have been met and no penalty is levied. Program is monitored by regulatory bodies.

Project

Solution

Plant walkthrough leading to Detailed Functional Design Specifications Software Design, Development, Migration from various open and legacy platform to Siemens platform (S7 and PCS7) Control system Hardware and Software testing (FAT and SAT) Installation and commissioning supervision Project Management
Standardization leading to higher Re-Use Highly structured Documentation Knowledge base (IP) for future Information Infrastructure for Integrated Enterprise of tomorrow Offshoring: Upto 65% of total project efforts were executed at offshore
26 March 2014 12

Value Add

Smart Automation development phases

Features Integration of tools Common APIs Single touch generation

Project Integration

HMI/ SCADA development

Tools and templates for.. Static screen generator Faceplates Dynamic Code generation for Soft and Hard I/O database HMI database Standard device Function blocks Process function blocks Tools to generate FDS SDS System Architecture Bill of material FAT & SAT procedure

Source code generation

Design Documentation automation

26 March 2014

13

Control system design documentation automation

CONVENTIONAL
Approval Approval

INPUT Contract
P & ID SSB Schedule Query Resolution Technic al Query

FDS

SDS

System BOM

Soft I/O Tag list

Hard I/O Tag list

HMI/ SCADA Database

With Smart Automation

Project Data Project info

Ref. doc info Process area info

FDS

INPUT DATA SDS

SDS System architecture

System BOM Soft I/O tag list Hard I/O tag list HMI/ SCADA database

26 March 2014

14

Source code and HMI/ SCADA generation Automation

INPUT DATA Soft I/O data
DB 21 DB 22

Hard wired I/O data

DB 35 DB 36 DB 37 DB 38

HMI database
DB 108 DB 109 DB 115

Standard Device Program blocks

FB 401 FB 402

Tools/ templates for HMI/ SCADA

Graphic conversion tool Converts screen shots of static graphic in word document to present for customer review.

Faceplate technology Pick and drop faceplates from customised

library Pass only required parameters in the block

Tools under development and testing

Process program block generation System hardware configuration Static screen generator

SCADA prefix technology

26 March 2014

15

Case Study Chemical Slurry blending system

Control system standardization and migration
Client US based hi-tech manufacturer Exiting Machines were programmed in a classical way, without State Flow Diagrams The PLC Logic is suffered from Maintainability and Scalability. Difficult to migrate to the higher platforms of controller of the same vendor. Lack of proper documentation. State flow diagram was created for the existing PLC Logic. Which served as a base line for Modular programming. SFD are linked to physical and internal address of the Machine. Modular- reusable function were created. User Manuals and maintenance manuals are connected to the PLC/HMI program and Schematic and wiring diagrams. Tools: RSLogix 500 Ver 7.00, Panel Builder 32 Ver 3.82, RSLogix 5000 Ver 13.00, RS View 32 Ver6.50, AutoCAD 2006, RS View Studio ME, Adobe frame maker Ver7.00 State level modular programming. Easier to maintain and update future PLC Programs. Program , P&ID and Wiring Linked. Migration to higher platform easier. Easier to troubleshoot machine operations- Reduction in downtime.
26 March 2014 16

Problem

Solution

Result

Engineering IT services

26 March 2014

17

Engineering Documentation services

Drawing Digitization / Migration
Hardcopy to digital format Migration between AutoCAD & e-Plan Engineering data management system implementation in SmartPlant Plant Engineering Data Life Cycle Management Field engineering Electrical Detail Engineering
Equipment Specification MCC Design Lighting Engineering

Field engineering
Lighting/ Earthing Layout
Installation BOM Cable layout Drawing

Instrumentation Detail Engineering Instrumentation System Design

Instrument Index Instrument Data Sheet Technical Validation Instrument Order Specification Instrument Interface details

Cable Schedule Loop drawings Instrument Hookup drawings Installation BOM Cable layout Drawing

Electrical System Design

Power flow strategy Electrical Audit

ELECTRICAL

ENGINEERING

INSTRUMENTATION

ENGINEERING

26 March 2014

18

Engineering through SmartPlant

SmartPlant Enterprise is a comprehensive product suite offering increasing value from IT in order to improve project execution, handover, and plant operational efficiency.
SmartPlant P&ID SmartPlant Instrumentation
3D Modeling and Visualization Engineering and Schematics

SmartPlant Process Safety SmartPlant Sketch

SmartPlant Enterprise

SmartPlant Electrical

Materials Management and Project Controls

Information Management

26 March 2014

19

SmartPlant Enterprise for Owner/ Operator

26 March 2014

20

TCS Services SmartPlant Instrumentation and Electrical

Implementation and project setup consultation

Consultancy

Migration consultation

System Architecture design and implementation support

Data Migration from other formats to SmartPlant

Implementation

Customized interface development for migration Customized Reports generation,

SmartPlant upgradation services

Interface with DCS, ERP and other third party software Post implementation support

Maintenance

Audit of existing database; Recommendation of optimization

Training

User training

26 March 2014

21

TCS Value Add

Wide horizontal competency to provide complete Life cycle Asset Management solution across Smart Plant Enterprise platform

Large expert pool in implementing business layer solutions as well as development of custom built interfaces

Dedicated practice to provide automation solutions involving instrumentation engineering, electrical engineering and control system design and development

In depth understanding of industrial domain

Matured project management methodology

26 March 2014

22

Migration to SmartPlant
DATA GATHERING
Sp ecs Dwgs & Docs - Hardcopy Dwgs & Docs in Soft format

1-2-3

Smart Suite

M I G R A T I O N

ADMIN

LAN INTERNET ROUTER REMOTE CONNECT ROUTER

Centralized Data Base SPI Server

T R A I N I N G

USER Training

26 March 2014

23

Onsite-Offshore Access
USA O N S I T E DIRECT CLIENTS
ADMIN

Local Area Network

Data Base Server Oracle

ROUTER

ONSITE - USERS OFFSHORE - USERS

O F F S H O R E
INDIA

INTERNET ROUTER

Local Area Network

REMOTE ADMIN

CITRIX NEIGHBOURHOOD

26 March 2014

24

Support Documents Required by client

26 March 2014

25

Project Categorization
Following chart displays project classification in terms of project billing for this financial year

Consultancy Design

2%
1%

Development

1%

85%

Implementation 11%

26 March 2014

26

TCS Automation Lab Infrastructure details

Project Management MS - Project PrimaVera P3 Configuration Management MS Visual SourceSafe PVCS

Automation Systems Controller platforms HMI systems Testing tools

Engineering Design & Documentation AutoCAD (2000-06, Electrical) E-Plan SmartPlant Enterprise SmartPlant P&ID SmartPlant Instrumentation SmartPlant Electrical SmartPlant Sketch SmartPlant Review Project Management Tools TCS - Integrated Project Management System

26 March 2014

27

Control System Infrastructure - Software

Sr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Make GE GE_FANUC GE-FANUC MITSUBISHI MITSUBISHI QUANTUM Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell SIEMENS SIEMENS Type SCADA Package SCADA Package Logic Software Logic Software Simulation software Logic Software Driver executive lite KEPServer Logic Software Logic Software Professional RS LINX Professional RS Logics 5000 DVD RS Logics 5000 DVD RS Net works for Ethernet/IP RS Networks for control net RS Networks for device net RS SQL RS View 32 Extensions RSSQL TRIAL RSView32 Works32K SCADA Package Simulation software Logic Software SCADA Package Details Unlimited developer iFix V3.5 (SCADA) Cimplicity Proserver 35000 tags Versa pro. Tool for programming PLC GX Ddeveloper GX Simulator Unity Pro Software Package for Three liscence package Rel. 3.01.00 V3.20(CRP 6) RS Logix 5000 Proedition english(9324-RLD700NXENE) RS view studio for machine edition(9701-VWSTMENE) V3.20(CPR 6) V2.43.01(CPR 6) Driver configuration and communication V13.03.00 Firmware kits,Documentation & service packs versions 10.06.00 through 13.03.00 V 5.11.00 V5.11.00(CPR 6) V5.11.00 (CPR 6) V7.50(CPR 6) RS view TrendX, Messenger, SPC,RecipePro, RSLadder Database management Graphic development RS VIEW WORKS 32K with RSLINKX(9301-2SE2403) RS Logics Emulate 5000 V13.00.00 STEP 7 Professional Development version Win-CC RC 64K Runtime+Development

26 March 2014

28

Control System Infrastructure - Hardware

Sr.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Make
Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Rockwell Quantum Quantum Quantum

Item Description
Control-Logix Processor with 750K memory. 7 slot chassis Chassis Power supply Control Logix series Ethernet Bridge module Control-logix battery Digital Input module 32 point Digital Output module 32 point Analog Input module 8 channel Analog Output module 4 channel Control Logix series DH+/ RIO communication module Control Logix series Control Net Communication module Control Logix series Device net communication module Flex series Control Net adapter module Flex series Device Net Adapter module Flex series Ethernet Adapter module Control Net Coaxial cable Control Net T-TAP Control Net Terminator Plugs Control Net co-axial connectors Flex series Remote I/O adapter Flex Series Digital Input module 32 point Flex Series Digital Output module 32 point Flex Series Analog Input module 8 channel Flex Series Analog Output module 4 channel Flex series Terminal base Flex series Terminal base for 32PT. modules Quantum CPU, For Unity Basic Level Power Supply 115/230VAC, Summable, 11 Amp [in Stand alone] Network Option, Ethernet TCP/IP and Modbus, FactoryCast embedded Web Server, Twisted Pair & Fiber Link, 1 Channel

Cat. Code
1756-L55M12 1756-A7 1756-PA72 1756-ENBT 1756-BA1 1756-IB32 1756-OB32 1756-IF8 1756-OF4 1756 DHRIO 1756-CNBR 1756-DNB 1794-ACN15 1794-ADN 1794-AENT 1786-RG6 1794-TPR 1794-XT 1794-BNC 1794-ASB 1794-IB32 1794-OB32P 1794-IE8 1794-OE4 1794-TB3 1794-TB32 140CPU31110 140 CPS11420 140NOE77110
26 March 2014 29