16.
3 SALIENT FEATURES OF DCS
16.3.1 System shall run on the latest Windows 7/latest for engineering station and operator
station. The system shall support the following :
(a) Open Ability to run third party application
(b) Multitasking Pre-emptive, with high responsiveness
(c) Human Interface Comfortable look and feel of GUI-ICON interface
(d) Interconnectivity Standard Interfaces like OPC etc.
(e) Networking Should support standard Ethernet TCP/IP, Modbus
Protocols by default.
(f) Integration Should provide seamless integration with minimum Glues /
Patchworks
16.3.2 System Architecture
[Link] System Architecture should be secure and deterministic. Each processor in the data bus
system shall perform dedicated functions and the system shall be capable of
determining the system performance at any stage of the system implementation.
[Link] The Open side of the system shall run on IEEE 802.3 (TCP/IP on Ethernet) standards
and will be used as the information network with connectivity to Desktop PC
environment. This shall be Information Domain.
[Link] The operator station shall directly connected to the Main Bus running on IEEE 802.4 or
802.5 (Token Ring or Token Bus) to facilitate Determinism in the Data transfer. The
plant bus and the lower control modules will form the control Domain.
16.3.3 Networking and Security features
[Link] The Node connectivity on the open side shall support Network infrastructure based on
TCP/IP protocols.
[Link] Network access security with rights.
[Link] Minimum of three access levels viz. Operator, Engineer, Manager for access by third
party applications and Workstation management.
16.3.4 MMI Requirements
[Link] Area/Group/loop wise plant control functions.
16.3.5 Graphics capabilities
[Link] Multi-window capability with Display management tools shall be available as options
[Link] Flexibility to the operators in terms of interactive graphics
[Link] Dedicated Alarm view availability while operating through the Process graphic.
[Link] System MMI should have the capability of the following information. Operator Logs
(Should have write access to operator). It should be possible to launch the above
information through an operating graphic. eg. calling up a procedure during operation.
[Link] Operator, Engineer or Manager should be able to view and edit, with appropriate
authority, the global database.
[Link] Engineering Station should be able to carry out all the above functions in addition to
System configuration, Station function building, database generation, Graphics editing,
Self documenting, System maintenance and Remote diagnostics.
16.3.6 Data Exchange Procedure
[Link] Shall support Real time process data (with Time stamp) availability on the plant
information network to be viewed at desktop PCs.
[Link] Any third party system supporting the above Industry standards should be able to
interact with the system with minimum Glues or Gateways.
[Link] Data Exchange between Information and control domain shall have access security
levels defined in the security features.
16.3.7 Engineering Tools
[Link] The tools shall facilitate both Online and Offline Engineering of the system
[Link] Engineering tools to build Graphics and database shall be available on a standard
desktop Environment viz. Win NT or 2008/latest Operating system.
[Link] Graphics/Database tools shall comprise of easy use of GUI Icons/Menus to facilitate
faster implementation.
[Link] DIAGNOSTICS: It shall be preferred to have a dedicated central diagnostic display
station for automatic display and recording of any system disturbances and enhancing
the system availability. For these, all processors, modules, cards, operator console,
transmitters etc., shall have on-line self diagnostic features which shall be displayed at
equipment / module level and inform to the central display station to display the fault
with equipment / module identification in clear text. All types of faults and disturbances
in all modules used in the system shall be automatically displayed and printed in English
only. The software shall enable display of I/O details such as cabinet number, module
number, and channel number, marshalling cabinet number, termination details and all
related attributes.
16.3.8 System Upgradation
[Link] If any up-gradation of the offered system is envisaged before completion of the job to
meet the specified requirements, the same shall be incorporated in the system, with the
approval of the OWNER without any additional cost. The newly offered C&I system
would have support of up gradation even after commercial run of unit for considerably
sufficient period (Approx. 10 years) without any extra financial burden/ implication to
Owner.
17.0 DISTRIBUTED CONTROL SYSTEM (DCS)-SUB SYSTEM DESIGN REQUIREMENT
17.1 MEASUREMENT SYSTEMS (MS)
Measurement system shall be complete with processor, signal conditioning and
monitoring cards and function cards to perform measurement system functions. The
system shall also be capable of transmitting the data to Operator Stations (OS)s /
LVW in the Unit Control Desk (UCD) and to Unit Control Panel (UCP) for display
besides transmitting the data to the peripherals.
17.2 CLOSED LOOP CONTROL SYSTEM (CLCS)
Closed loop control system shall be complete with redundant processor, signal
conditioning and monitoring cards and function cards to perform control system
functions. The system shall also be capable of executing commands from OS / LVW
through key boards located in the Unit control desk (UCD) and transmitting the
data to OS /LVW for display besides transmitting the data to the peripherals .
17.3 INTERLOCK, PROTECTION AND SEQUENTIAL CONTROL SYSTEM (OPEN LOOP
CONTROL SYSTEM)
Interlock, protection and sequential control system shall be complete with redundant
processor, signal conditioning and monitoring cards and function cards to perform
the sequential and combinational logic functions. The system shall also be capable
of executing commands from OS / LVW through key boards located in the Unit control
desk (UCD), and also from Unit Control Panel operational hardware besides
transmitting the data to the peripherals.
17.4 DATA BUS SYSTEM (DBS)
The communication sub system shall be a real time reliable communication network
between control processors, MMI (Operator Stations, Printers) and Engineering station.
The main bus shall have dual redundancy.
17.5 OPERATOR STATION (OS) / MMI SYSTEM
TFTs/key boards/mouse of OS, printers and associated hardware form the Operator
Station (OS)/MMI. The data communication between TFT/key boards/mouse,
printers and processors is through the data bus.
17.6 HISTORISATION AND RETRIEVAL FACILITY
Historical storage and retrieval facility shall allow collect and store data and parameters
including trends, alarms and events from DCS data base periodically and automatically
to removable data storage devices once every 24 hour for long term storage and
retrieval.
17.7 ENGINEERING STATION (ES)
ES equipment shall have work station & printer to perform the functions of software
generation and maintenance of DCS system in addition to OS functions. It shall also
be used for monitoring the status of all equipment connected to DCS system. The
system is detailed in relevant Section-D 5.4 of this specification.
18.0 DCS EQUIPMENT / SYSTEM – FUNCTIONAL REQUIREMENT
18.1 DISTRIBUTED PROCESSING UNIT (DPU)
18.1.1 Processor will be minimum 32 bit with floating point arithmetic capability. It will have
adequate capacity of non-volatile memory to store dynamic plant data, control
programmes, operating system software, standard software to perform control data
acquisition and diagnostic functions. Memory expandability of 150% of offered capacity
shall be provided. No battery backup memory is allowed.
18.1.2 Processor shall have the following functional capabilities as a minimum:
(a) Mathematical Functions: To meet the functional requirement of the control
system and provision to add more algorithms by the purchaser.
(b) Logic Functions : For performing Boolean operations and time delay
requirements
(c) Control Techniques: Shall include Multivariable, feed forward, feedback,
cascade, auto tracking, ratio and bias, dynamic dead band, proportional,
integral, derivative and their combinations, auto inching, auto limits, blocks, run-
ups, run downs, over rides, analogue hold and any other techniques as may be
necessary.
(d) Point Status and Quality feedback.
(e) In addition to the above feature of the CPU, Fail safe CPU card shall have the
following additional features.
i. CPU- Dual processor, 1oo2 architecture.
ii. Mode of operation- Safe mode( by default) / Maintenance mode
iii. Safety level- TUV certified for use in a safety function up to level SIL 3
iv. Compatible to safety standard IEC 61508/615111,DIN/VDE V19250
v. It shall be provided with Safety Firmware.
18.1.3 INPUT/OUTPUT MODULES
[Link] Digital Input Modules shall have the following features:
(a) Signal isolation (optical)
(b) Fuse protection
(c) Contact bounce protection
(d) Field cable monitoring
(e) Short circuit protection
(f) Configurable as status input, latched input
(g) Alarming of abnormal state
(h) The interrogation voltage for digital inputs shall be 24 V DC
The number of channels per DI module shall be maximum 32
[Link] Digital output Modules shall have the following features:
(a) Individually fused
(b) Individual contact suppression
(c) Configurable as momentary, latched or pulse-width modulated outputs
(d) Individually definable default state
(e) Output read back verification
(f) Short circuit protection
(g) The O/P channels will be rated for 24 vdc interposing relays.
The number of channels per DO module shall be maximum 32
[Link] Analog Input Modules shall be HART compatible and shall have the following
features:
Analog inputs can be 4-20 mA DC, RTD ( Pt 100 ) , Thermocouple
(a) Signal isolation (Galvanic/ Opto-coupler)
(b) Fuse protection and fuse failure detection
(c) 2-wire transmitter loop power supply at 24 V DC
(d) Input filtering for noise level
(e) Cold junction compensation for thermocouples
(f) Transmitter monitoring for parity, wire break and limit values
(g) Monitoring of A/D conversion
(h) Conversion to engineering units
(i) Test for normal or extended range
(j) Detection of open circuit for thermocouples/RTDs
(k) Detection of open circuit for thermocouples
(l) Alarm limit testing for high, high-high , low, and low-low substituted values
The number of channels per AI module shall be maximum 16
[Link] Analog Output Modules shall HART compatible and shall have the following features:
(a) Analog outputs shall be 4-20 mA DC for 600 ohm (load)
(b) Direct or reverse operation
(c) Loop check back of output
(d) Default options upon failure
The number of channels per AO module shall be maximum 16
18.1.4 In addition to the above feature of all I/O cards, all fail safe I/O modules(DI,DO,AI& AO)
shall have the following features:
(a) CPU- Dual processor
(b) Module shall be internally fully redundant.
(c) Complete internal diagnostic feature shall be provided.
(d) High immunity to EMI
(e) Conform to safety standards such as IEC 61508/615111,DIN/VDE V19250
(f) Safety level- TUV certified for use in a safety function up to level SIL 3
(g) It shall be provided with Safety Firmware.
18.1.5 If remote I/O modules are used then the I/O modules shall be interfaced with controller
through redundant I/O bus. Fibre Optic cable shall be employed for I/O bus with
necessary copper to Optical converters.
18.2 Design Features/Requirements of Process Controllers (DPU)
18.2.1 Microprocessor based multi-loop controllers with input / output ports/cards shall be used
with configuration and control software. All open/close control loops shall be easily
configurable using user-friendly software. Controllers shall be able to operate in either
manual, auto, cascade mode. Mode changeover in either direction shall be bump less.
All controllers shall be freely configurable with respect to requisite control algorithms.
18.2.2 The controller should be capable of implementing complex and advanced control
strategies through the use of exhaustive set of control algorithm/software blocks. These
shall include PID, adaptive, feed forward, dead time, lead-lag compensation, high-low
signal selection, curve fitting, real time computational capability etc. In addition the
controller shall be able to perform batching, sequencing, interlocks and logic functions.
Failure of one loop shall not result in failure of other loops.
18.2.3 The distributed processing unit shall be provided with redundant floating power supply.
The power supply modules, which are vital to the system’s continuous operation, shall
have the means to receive power from two (2) independent power sources.
18.2.4 The system shall have 1:1 redundancy with respect to the processor modules, power
supply modules, communication modules and network interface for sequential and
closed loop control. The system shall be designed in such a manner that in the event of
failure of the primary controller, the entire configuration of the failed controller shall be
instantaneously and automatically transferred to the back-up controller without
operator’s intervention. Mode changeover in either direction shall be bumpless.
Simultaneously, a message should appear on the video-monitors of the
Operator's/Engineer's work station indicating the failure.
18.3 OPERATOR STATIONS (OS) / MMI SYSTEM
18.3.1 OS shall provide man machine interface for monitoring and operating the plant
equipment with the help of various graphics and displays and also generate various
logs/reports for effective plant operation.
OS shall be Freely assignable and have the following features as a minimum:
[Link] Plant Control Displays:
Control displays shall facilitate normal plant operation. These displays shall be
organised in the form of plant overview display, group displays, individual input/output
point displays and logical function displays. It shall be possible to perform both open
loop and closed loop control from these displays. The parameters like set point,
measured value, controller output, control deviation, deviation limits, controller tuning
parameters, sequence status and criteria, waiting and monitoring time, position of final
control element shall be monitored. Auto/manual mode change, set point/ bias/output
change, automatic/step-by-step, manual sequence control, criteria bypass, sequencing
and intermediate step operation shall be provided.
