Distributed Integrated Control System

Distributed Integrated Control System (DICS) includes Regulating Controls, Interlocking and Protection, Sequential Controls, Operator Interface Units, Monitoring and Information data archiving, Historical data storage and retrieval, Trending, Alarms & Reports.

Seller shall offer latest system available with him & shall also confirm that DICS system hardware / software shall be upgraded free of cost, for hardware upto commissioning of the project and software upto 3 years after commissioning of the project.

The DICS shall receive process signals from field sensors &

transmitters and shall give commands to final control elements, alarms, trip relays, etc. All signal converters, to convert sensor signals to standard 4 to 20 mA signals shall be included in Seller‟s scope of supply.

High ended DCS System with stand by communication redundancy should be placed at Mill house, Clarification & Evaporatio n section, Pan Boiling section and Boiler/Power generation section in air-conditioned control room with air curtains at doors to maintain the temperature of 27 deg.C.

2.14.5.1 Introduction and Gene ral Require ment

Distributed Integrated Control System (DICS) shall comprise of the following sub systems operating in completely integrated manner employing the same family of hardware and software.

i) Processor stations/sub system:- where function of closed loop control system (CLCS), open loop control system (O LCS) and Measurement (Including Signal Acquisition, Conditioning, Distribution, Transmission, Indication and Recording) are realised.

ii) Operator Station/sub system:- which together with their branded computers, monitors other peripherals perform operatio n and monitoring functions including data archiving & alarm monitoring etc as per purchaser‟s choice.

iii) Programming, and on line diagnostic station (Maintenance Purchasers Station):- for system programming, system configuration, system and instrument fa ilure detection and trouble shooting.

iv) Communication Network: The system shall be distributed and various sub-systems shall be integrated through a system of communication on Ethernet network. The man machine interface between the operator and plant shall be through flat screen monitors, key board and mouse.

v) Field Instruments: All process sensors & transmitters shall be provided for sensing process parameters. These shall be of smart type with local display and ability to be monitored / re-calibrated from the Purchasing station.

2.14.5.2 Basic Features/Design Requirements 2.14.5.2.1 Design Require ments

1 The instrumentation and controls shall be designed for maximum availability, reliability, operability and maintainability

2 All I&C equipment shall be designed for their specific application within the sugar mill and shall be furnished for required control, protection, alarm and remote monitoring.

The application and selection of these I&C equipment including signal converters, interposing relays, microprocessors, etc. shall be the responsibility of I&C Seller.

3 All I&C equipment furnished must have proven experience of working in the sugar factories, at least two sets of such equipment installed in a similar sugar factory have been running successfully for at least two years. No prototype components shall be used.

4 DICS shall be of latest design, not be more than 3 year old.

The control system shall be highly modular and arranged to

reflect the grouping of plant equipment and systems to be controlled.

5 Any local junction termination boxes or auxiliaries which are required to implement the interface design shall be supplied by I&C Seller.

6 Control system shall comply with following general failure criteria :

a No single fault can cause the complete failure of the control system.

b The grouping of control functions into system block s shall be arranged such that failure of any one block will only partly degrade the control of the overall system.

7 To meet the above failure criteria the I&C system shall incorporate self- checking facilities so that internal faults can be detected within the system itself.

8 Alarms shall be provided for all abnormal conditions of the process.

9 The following colors shall be selected for equipment status indications:

Green Energized, Running, Valve Open Red De-energized, Stopped, Valve Closed Light yellow Abnormal condition, Discrepancy

White Control Power Available

10 The DC and AC power of each control and monitoring system shall be derived from two independent sources and float charged batteries shall be furnished to guard against the total loss of power supply.

The system shall be provided with extensive diagnostic features so that a system failure can be diagnosed down to the module level giving location and nature of fault. Ease of maintenance and trouble-shooting shall be a primary consideration in equipment selection.

The offered system shall have windowing capability with atleast splitting up one screen into four different sections to monitor four different areas/information face plates in the same screen.

2.14.5.2.2 System Architecture

The operating station and Engineering station shall be connected on open network , either on Ethernet TCP/IP or Control net in order to mak e the system open. All operating stations shall be interchangeable and operation of the plant shall be possible from Purchasing station if required.

The system shall have built in redundancies for all system functions at the processor. No failure of any single network shall lead to any system function being lost. It shall have redundant open type network on a "masterless" principle.

The system shall have the capability and facility for expansion through addition of station/ drops, controllers, processors, process I/O cards etc.

The application programs for the functional controllers shall reside in EEPROMS or in non volatile RAMS. The application program shall be alterable by access through programmer's console.

2.14.5.2.3 Main Controller Characte ristics

Each controller envisaged for this project shall have following features as minimum:

i) Processing length of 32 bit ii) Watch Dog timer

iii) Memory protection

iv) Self monitoring & diagnostic feature v) Easy modification of control functions

2.14.5.2.4 Processor System (Automation System)

The analogue/binary input/output modules, drive control module for analogue control/open loop control, function group control module etc. shall form part of the Process Station. The control system should not have more than ten different types of module s.

The system with reduced number of different types of modules/cards has the advantage of easier servicing, modification, reduced spare inventory & hence the same shall be preferred.

2.14.5.2.5 Analogue Input/Output Modules

Analogue input/output modules s hall be capable of accepting TC&RTD (Universal Card), 4-20 mA current.

It shall have the following features:-

a) High accuracy of conversion, min imu m 12 b its, plus sign bit.

b) Linearisation and error checking of TC and RTD signals and reference junction temperature correct ion facilities for T/C.

c) All the inputs shall be isolated to 600V.

2.14.5.2.6 Binary Input/Output Modules

The Binary signal conditioning processing shall be performed in distinct binary input modules which can accept voltage free contacts, digital signals, and also pulse inputs. The modules shall process different inputs such as volt free contacts, proximity switches and logic signals.

The binary input/output modules shall have the following features:- i) High insensibility against noises and other disturbance.

ii) High insensibility against over voltage (IEC-255-4 Class-II).

iii) Supply of contacts voltages - with 24 V DC

iv) Signal status indicators by LED's on the module front

v) All the inputs shall be isolated to 600V between any input point and ground or between any pair of inputs & shall comply with ANSI 37.90a fo r transient surge protection to 2000 volts.

vi) For Pulse Inputs provision shall be made to receive and accumulate pulse inputs in the form of repetitive contact closures.

2.14.5.2.7 Close Loop Control Functions

The following control algorithms shall be possible as a minimum in respective processors:

i) P, PI, PID ii) Square root

iii) Addition/Subtraction iv) Linearisation

v) Multiply/divide vi) Ratio (Scale)

vii) High/Low signal selectors viii) Totalizers

ix) Manual loading

x) Lead- lag compensation xi) Feed forward controller xii) Over ride

xiii) Multivariable control

xiv) Nonlinear control algorithms xv) Biasing

xvi) Mean (average)

xvii) Median value selection - analog xviii) Two out of three logic - digital Open Loop Control Function

Functional group control module for open loop control system shall perform the functions of sequential operation, interlocks and protection.

It is intended to control the unit automatically through a number of sequences with operator's intervention for initiation of each sequence. The sequence shall be executed as per the defined program.

2.14.6 Operator Station, Operator Control, Plant Information And Monitoring Stations/Operator Sub System

Ope rator Station

Operator station shall perform operator control function, plant monitoring and display function, alarm functions, logging functions, historical data storage & retrieval functions. Total two (2) Nos. of operator stations are envisaged for each section to execute all the functions specified above & elsewhere in specification. Minimum 64 bit computers along with all the peripherals shall be provided for operator stations.

Ope rator station Specification:

 P4 ( C 2 D core to due processor), 1 Ghz, 512 MB RAM, 80 GB Hard Disk,

 1.44MB HDD, 54 x CD ROM, 2 Serial Ports,

 1 Parallel Port, 2 USB Ports

 17" Flat Screen Colour Monitor (TFT)

 HP inkjet Colour Printer

All functions required for supervision & remote manual control of the unit shall be performed by this station. The functions shall be performed with the help of standard pictures on monitors which shall include plant mimics. Issuance of control command shall be realized through wireless/cordless functional keyboard or optical mouse/trackball.

2.14.7 Plant Monitoring Display & Logging