Project Specific system requirements

1) The system should have a truly distributed architecture, both functionally & physically , designed following the philosophy of providing an open system using hardware , software and communication standard to maintain a long lived architecture.

2) All platforms on the system should use the same operating system and base system software so that operators , maintenance people , engineers and managers utilize consistent software tools and interact with the information in the same manner.

3) Time and date format shall be unitform through out the system and it shall be as per HH:MM:SS and DD:MM:YYYY format with 24 hrs. clock.

4) All hardware shall be protected against RFI , typical freq.

are 0.15Mhz ....1212 Mhz and especially 146 ....174 Mhz by walky talky of 6 ... 10 watts power in 1 m distance.

5) System’s software shall also include the software to configure the communication link between DCS & any PLC based or other 3^rd party control system capable of communicating on MODBUS RTU/ASCII protocol. Significant features and characteristics of the interface include

a) Availability of data in the interconnected PLC which allows the DCS to integrate in displays data from PLC and to centralize monitoring of PLC operating status.

b) Ability to write data parameters from DCS gateway into selected locations of programmable logic controllers.

5.0 TRAINING

5.1 Supplier shall train owner’s maintenance engineers as well as operations staff in his works. The training imparted shall be by qualified and experienced staff available. It shall be exhaustive and aimed at making clients’ maintenance & operations staff self reliant for most of the day to day applications. For training, supplier shall make available as close a model of the system with all the

envisaged that following be covered in the training:

5.1.1 Maintenance Staff Training a. System architecture.

b. Functions of each node.

c. Hardware in each node.

d. Complete application software.

This shall cover everything from basics like generation of various system nodes to advance language programming, configuration and debugging etc.

e. Commonly occurring hardware problems and the maintenance procedures to be followed.

f. Various diagnostic programmes available and their use and interpretation.

g. Routine preventive maintenance procedures.

h. Maintenance of various peripheral devices like printers, copiers etc.

5.1.2 Operations Staff Training

This shall be restricted to the operation of the system. This shall broadly cover the following:

a. System architecture.

b. Functions of each node.

c. Functions of various keys in the keyboard.

d. Generation of displays like graphics, group, trend groups, etc.

e. Display hierarchy, access methods for various displays, switching between different types of displays etc.

f. Control of plant from various displays.

g. Alarm handling.

h. Developing special programmes for plant control and their debugging (Restricted to supervisory staff only).

i. Logging software.

5.2 For purposes of training, detailed literature, instruction &

maintenance manuals in English shall be arranged by the BIDDER.

as under:

 6 Instrument engineers x one week each at vendor’s works.

 6 Process engineers x one week each at vendor’s works.

 Two Weeks training for Two Instrument engineers from each unit for DCS, at vendors centre of excellence.

6.0 INSPECTION

6.1 The system and all (100%) its associated components shall be inspected and tested at the BIDDER’s works by OWNER

6.2 OWNER reserves the right to inspect any bought out items by the BIDDER at the sub-BIDDER’s works.

6.3 Cost of inspecting/testing shall be borne by the BIDDER.

6.4 For final integrated inspection of the system, the BIDDER shall give a minimum notice of 3 weeks to Owner.

Through out the factory acceptance test, BIDDER shall provide all necessary test equipment’s and consumables and shall make all necessary connection to all hardwires as many times required.

OWNER shall carry out 100% functional checking of all hardware/software modules. BIDDER to co-ordinate with ESD system BIDDER for system integration and SAT.

6.5 The inspection shall briefly envisage the following:

6.5.1 Hardware Inspection

a. Checks on general workmanship like fabrication quality, paint quality, whether paint shade identical to all cabinets etc.

b. Dimensional inspection for base frame, height, depth, gland plates etc.

c. Power supply, wiring checks for fans, tube lights etc.

d. Supply/signal wiring checks including colour code checking, checking of ferrules, correctness of wiring, size of wires, proper segregation of wires etc.

e. Provision of terminals of correct size and type.

f. Operation of various lamps, push buttons, HRC fuses, annunciators, relays, ammeters and other instruments mounted on the consoles or within the cabinets.

g. Megger test for power distribution cabinets.

h. Provision of earthing bus bars for safety earth/intrinsic safety earth.

i. If a group of panels/consoles is to be mounted and bolted together in the final layout frozen the same shall be offered for inspection exactly in the same fashion to check inter panel wiring, mechanical alignment etc.

j. All system modules shall be checked for their correct mountings in respective slots as per configuration frozen.

k. Redundancy wherever specified shall be checked for:

i. Power supply.

ii. I/O cards ( if applicable).

iii. CPU/CPUS.

iv. Communication (between nodes as well as within a node).

l. Scan times as specified shall be checked for all inputs/outputs.

m. Individual modules wherever possible shall be checked for their performance.

n. All volatile memory shall be checked for battery backup by tripping power for the duration given in the BIDDER’s specifications.

o. For all items a~j inspection shall be 100% on all items.

6.5.2 Software Checks

These shall include, but not limited to, the following:

a. 100% check on the generated data base. This includes checks on:

i. Correctness of tag number and description.

iii. Input type, input conditioning.

iv. Algorithms to be executed.

v. Output type and conditioning if any.

vi. Other details if required.

b. All graphics shall be checked 100% for static and dynamic details. These include:

i. Checking all graphics for correctness w.r.t. P&ID.

ii. Checks on line thickness, colour, equipments, tags, units of measurement.

iii. Checking of modifier conditions wherever specified.

iv. Switching between various operating pages as per philosophy frozen.

v. Operation of all touch targets.

c. Operation of all keys on the keyboard shall be checked. Various printing operations like, operator changes, alarms, guide messages, screen printing etc. shall be simulated and checked at random.

d. Group displays shall be checked for correctness of grouping.

e. Alarm priorities shall be checked for all alarms.

f. All complicated loops shall be checked 100% from input stage to output for correctness of configuration.

g. All logic & sequence operations shall be checked 100% from input to output by forcing/enabling various I/Os through software.

h. Any higher language programmes shall be checked 100% either by simulation or by feeding requisite inputs and checking the outputs.

i. Logging operation shall be checked.

j. Communication between PLC and DCS shall be checked at site.

k. BIDDER to submit detailed FAT/SAT procedure along with offer.