Table of Contents
1. General
2. Miscellaneous
3. System Architecture
4. Functionality
5. Hardware Specification
6. System Software
7. Application Software and Configuration
8. System Services
1. General
1.1 Scope
This specification defines the requirements for a complete digital control system (DCS) for A______________plant at ______________.
The proposed control system shall be designed for an industrial environment and shall be capable to be expanded for future needs in a timely and cost effective manner with minimal operational interruption.
1.2 Basic Functions
The proposed control system shall perform the following functions:
a. Process control and monitoring via colour CRT’s and keyboards
b. Data gathering and manipulation such as data base management necessary to implement recipe generation and processing and ultimately allow a computerized plant management and information system (MIS)
c. Communicate with foreign devices such as, but not limited to PLC’s (=Programmable Logic Controllers). This communication is to be preferably supported by MAP (=Manufacturing Automation Protocol).
1.3 Definitions
Client :
Vendor :
Engineering contractor :
Purchasing office :
1.4 Language
All correspondence, specifications, drawings, documentation etc. concerning this requisition shall be in the English language.
Minutes of meetings shall be uniform and issued to all participating parties within one week.
1.5 Codes
This DCS shall be designed in accordance with all local statutory regulations such as:
1.6 Planning and Time Schedule
Planning dates
- DCS order placement :
- Training engineer(s) :
- Hard / software freeze date :
- Database generation :
- System configuration :
- Delivery development system :
- Factory stating :
- Factory acceptance test :
- System delivery on site :
- Site acceptance test :
- Training operators :
- Training maintenance :
The total project shall be divided into main sections, which include sections of the hardware and software developed. A split shall be made by dividing the main sections between the participating project members/departments and place of production. For each basic activity the following dates are required:
- Earliest date
- Latest start date
- Duration
- Earliest finish date
- Latest finish date
An overall planning in bar chart format, using “procedure planning” techniques shall be provided by the vendor. The bar chart planning shall indicate the progress made to date. The progress shall be indicated at regular intervals (normally on a monthly basis, unless circumstances dictate a different frequency of up-dates) by means of a critical path network, showing per item the lagging, on schedule or ahead of schedule situation. To assist controlling the progress a number of “milestone” dates shall be inserted into the overall bar chart planning. Progress meeting shall be held on a monthly basis at the purchasers offices.
1.7 Project Organization
In the event of an order the vandor shall assign a project team. The team shall be entirely responsible for handling the project from order date up to and including the acceptance of the system by the purchaser. The team shall be supervised by a suitably qualified project manager who will be the primary contact for interface between engineering contractor and the vendor for the duration of the project.
The Project Manager shall have overall responsibility to insure that all system objectives and schedules are met. In case of non availability of the Project Manager the next person in line of the project team must act on his behalf. In the quotation the project team members shall be proposed, their project responsibility, experience and qualifications shall be highlighted.
1.8 Standardization of System Hardware/Communications
Control system communications shall be based on rules of internationally known and recognizations, such as the International Standards Organization (ISO) Open Systems Interconnect (OSI) reference model to provide a migration path to evolving communications standards, such as (MAP) Manufacturing Automation Protocol. The communications system shall also support local area networks to optimize loading throughput.
The equipment shall be standard, commercially hardware wich is part of an existing product line.
1.9 Company Organization
Vendor shall clearly specify and document his company organization with respect to:
- Production facilities and location(s)
- Final assembling
- Factory quality assurance programs
- Staging facilities and locations
And in country of final installation:
- Service organization for hard- and software, including number of qualified engineers
- Spare part stock location and policy
1.10 Price Break Down
Vendor shall provide detailed prices/project discounts for all main items contained in the order such as but not limited to:
- Each unique individual hardware item
- Software packages
- Configuration software
- Project management
- System testing at vendors facilities
- System testing at site
- Documentation
1.11 Deviations from the Specification
In case vendor cannot meet the specification or can quote better alternative solutions, he shall clearly indicate these deviations in his quotation. Changes to the design, price or schedule will not be valid unless authorized by purchaser and engineering contractor and confirmed in writing.
1.12 Order Criteria
the vendor shall provide evidence of existing systems that use the same basic hardware, software and system concepts as the system being proposed.
The proposed system need to be upward compatible for the hardware and software.
A referance list of installed systems shall be provided.
If the project involves a complete new control system or in case of a complete newdeveloped control system, the vendor needs to fulfill the following order criteria:
- Vendor must give the client and engineering contractor the oportunity to pay a visit to a company who has a system of comparable or larger capacity that uses the same basic hardware, software and system concept.
2. Miscellaneous
2.1 Environmental Conditions
The control equipment shall operate in an air conditioned environment within a temperature range of 5ºC and 50ºC and 50% to 95% relative humidity (noncondensing) and thermal shock of maximum 1ºC /minute.
The operator interface shall operate within a temperature range of 15ºC and 30ºC and 80% relative humidity (non-condensing) and thermal shock of maximum 1ºC /minute. The equipment room(s) will be protected from fire by means of a halon-system.
2.2 Electrical Load
Vendor shall give an expected electrical load figure with cos (PHI) for the proposed control system and vendor shall also indicate the preferred system power distribution with individual load figures.
2.3 Surge and Overvoltage Protection
Surge protection is required as follows:
a. Protect all equipment power supplies from power line surges
b. Protect all equipment against surges induced on control and sensor wiring
c. Protect all communications equipment against surges induced on communications highway.
Communications link overvoltage protection is required to protect all equipment against overvoltage on any communicationa link.
2.4 Radio Frequence Interference (RFI) Protection
The entire system shall comply with Sama Standard PMC 33.1 - 1978 “electromagnetic susceptibility of process control instrumentatin”.
The equipment shall be RFI immune to at least Class 2 (10 V.m), bands a thru c (10-1000 Mhz). The output shall not deviate more than 0.1% of span.
2.5 Grounding
All metallic enclosures of electrical equipment shall be grounded in accordance with _____. Vendor shall state in his quotation if a clean computer grounding and/or additional special system grounding is required.
2.6 Heat Dissipation
Vendor shall give figures for the excepted heat dissipation.
2.7 System Reaction Times
After call-up from the key-board the ultimate delivered system will present the following displays within the specified time (minimum requirements):
Group/Loop displays 2 sec.
Graphics with 50 variables 3 sec.
Paging instantaneous
Real time trend curve 3 sec.
Real time multi trend 5 sec.
Historical trend curve 10 sec.
Screen refeshment rate 1 sec.
Extern contract to screen 2 sec
Keystroke to output contract 2 sec
Test shall be a full working system and the above stated times shall be guaranteed by vendor with all software loaded and operational.
2.8 Key Levels
The standard control package shall have several definable key levels for access to the data-base via the keyboards. The key levels shall have hardware keylocks or password protection.
2.9 System Limitations
Vendor shall clearly state all system limitations but special attention shall be given to the following points:
Hardware :
- maximum number of input/output signals,which can be attached to and handled by one control processor.
Software :
- maximum number of signals, types and blocks, which can be processed per control processor at an average scan rate of 0.5 second maximum number of block equivalents used memory per control processor
SCAN time :
- minimum total scan time per controller including I/0 coupled with a loading figure
Operator monitor :
- maximum number of signals what is the available space in the controllers for application programs with respect to: 1) Ram 2) Number of levels 3) Number of blocks
Number of graphics :
- minimum 200
Number of variables/graphics :
- minimum 50, a variable is a data base point, e.g. 1 x Sol. valve output, 2 x valve position, 1 x elasped travel time total 4 variables. The graphic symbols can be controlled by those 4 variables and in a combination
Number of real trends :
- minimum 200/operator system
Number of historical time trends :
- 500 on the (future) host for 4 weeks based on 6 minute samples
- 200 on the operator system for 3 days, based on 1 sample
Disk size :
- Vendor to specify for above mentioned trend storage
Program down loading time :
- minimum 1 minute vendor to specify if from development system controller partial loading are possible
Controller loop execute time :
- up to 1/4 second for a limited number of loops
Discrete input recognition time :
- up to 0.1 seconds for a limited number of points.
2.10 Licenses
If any software licenses are involved it should be included in the quotation. After order placement any further will not be considered.
3. System Architecture
3.1 General System Levels
The system architecture shall consist of the following:
- Process interface
- Operator interface
- Provisions for future connection with a host computer
- Interface with foreign equipment.
All those units shall be connected via a system network.
The network protocol shall provide for:
- Communications with the process interface
- Communications with the operator interface
- Communications with the future host
- Communications with the foreign equipment.
The protocol shall support all min tasks to be carried out by the system such as transmission of set and read commands, reporting, automatic bypassing of failed units, etc.
3.2 Foreign Equipment
In addition to vendors standard equipment, foreign equipment like PLC’s and analyzers may be connected to the system (via RS 422A channels).
The vendor is also requested to state if communication with so called “intelligent” transmitters is supported.
When available, vendor shall specify his standard available interface protocols for PLC’s, analyzers and inteligent transmitters in his quotation.
When required the communication protocol shall be developed by Vendor on the bases of the foreign equipment information supplied by subsppliers and comply with standard as developed by CCIT or ISO, it shall be noted for standardization purposes that MAP (Manufacturing Automation Protocol) is preferred.
4. Functionality
4.1 Process Interface
The process interface will consist of the microprocessor based controllers and input/output circuitry. These components are installed in dedicated system cabinets.
Operator intervention will take place via the operator stations and the network.
In case of communication failure, the controllers will continue to operate on the last set of parameters. In such a situation a system diagnostic program will give a system alarm message to the operator.
The controllers will use an integral control package to perform all plant control tasks. The plant control tasks consist of combined “analogue” and “discrete” control and shall also contain on top of this first layer a sequential logic performing more enhanced tasks. This application software shall be configurable.
4.2 Operator Interface
the operator interface is located in the central control building.
The operator interface used two (2) operator stations containing three (3) color CRT’s with keyboards. For redundncy the color CRT’s are connected to different micro-processor systems, however, operator station data bases may not necessarily be equal.
Each display computer system is basically identical and performs all necessary tasks to sustain the operator screen with:
- Interactive graphic displays
- Historical trend curves
- Real time trend curves
- Alarm overviews/history
- Alarm priority level
- Group/loop control displays
- Batch menus and status
- System diagnostics
- Shift reports
- Plant reporting.
In addition some dedicated hardware is also included such as:
- Shutdown and selector switches
- Hardwired recorders
- Miscellaneous equipment.
Furtermore printers and an engineering/supervisory console is envisaged.
4.3 Batch and Sequence Control
The vandor shall provide all necessary hardware and software to allow for typical batch and batch related function such as (but not limited to):
- Recipe handling
- Batch scheduling
- Discrete and continuous control
- Operator intervention
- Failure sequences
- Interlocking
- Report generation
The vendor shall clearly specify which hardware and software is designated for batch and sequence control.
4.4 Host (Future)
Note: Vendor shall indicate in his quotation if a host computer is required as a database building tool.
The host system will be used for additional tasks, such as:
- Central data acquisition and storage
- Optimization of complete plant units
- Central logging of allarms on disk and printer
- Engineering information center
- Raw material, produce inventory and quality control
- Heat and material balances
- Utility usage and energy management.
The communication speed between the host and the DCS system shall be at least 200 tag points per second.
4.5 Expansion/Maintenance Flexibility
Vendor shall indicate if modifications to the system software and hardware can be performed online without interrupting the normal plant control.
4.6 Availability
Optimal system availability is a prerequisite.
This will require the inclusion of the following features:
- Redundant system bus techniques
- Redundant controllers with automatic transfer function
- Single loop integrity and A/M transfer station
- Redundant operator stations features
- Redundant power supplies
- Internal battery back-up on memory cards
- Common power connections for 24V DC main power supply system (Battery bank) or in case of AC supply:
- 2 separate power connections (2x220v ).
All output cards shall have a default fail state. The status will be determined from: communication failures, supply failure and card failure.
Multi-channel analog output cards shall have an auto/manual statiofacility to enable replacing the card without disrupting the field signals. The auto/manual (and reverse ) actions shall be bumpless.
A certified system reability analysis shall be provided for the total system quoted. The analysis shall include mean time between failure (MTBF) and availability values of every module emploied in the system. A mean time to repair (MTTR) of a failed item shall be set at 8 hours for all self revealing failures.
Vendor shall give above requested figures with quotation.
For unrevealed faults a test interval of 168 hours shall be used to establish fractional dead time.
The following definitions for failure shall be applied:
- Coincident loss or more than one control output
- Loss of operator access to a single loop through one operating station
- Loss of operator access to all loops through one operating station.
The total system MTBF and the availability figures shall be established for each case. To provide a high system availability it is anticipated that every failure can be rectified by circuit board, sub-assambly, keyboard, CRT unit, disc drive or power supply replacement wiyhwin 8 hours. To access the Vendors recommandations for spare parts for such maintenance, MTBF figures shall be provided for all such components employed in the system quoted.
4.7 Loading Factors and Spare Capacity
Vendor shall quote a system loading factor based upon the specified hardware information and software information (ref.7.4 and 8.2).
Hardware loading :
- 70% of system I/O and other system cmponents capacity.
Software loading :
- 50% available free custom configurable software capacity.
5. Hardware Specification
5.1 General
All equipment is classified as “nonhazardous” and shall comply with the electrical code_____ .The equipment shall be completely assembled and wired to standard terminals in order to connect the supply, grounding and signal cables.
Cable channel/trays for incoming cables shall have ample space for installation.
Cable trunking shall be filled up to maximum 75% of the area. The calculation is based upon (total wire cross section including insulation/trunk *100%. All signal cabling will enter at the bottom of the cabinets.
Cabinets shall be provided with lift-off doors. Doors shall have provisions to store manufacturer’s drawings.All system cabinets shall have a key-lock. One key will give entrance to all cabinets.
Electronic circuitry shall use plug-in cards mounted in19” racks
Cards shall be designed for on-line replacement (with a fully powered system).
Vendor shall specify the system power supply requirements per unit/item with respect to:
- Over/under voltage
- Surge/slugs
- Impilses
- Frequency shift
- Ripple/spikes.
All plug connections (if any) shall have gold plated connectors.
Field signal connections shall be wired to terminals strips.
Internal power cabling shall be minimum 2.5 mm2
5.2 Process Interface
5.2.1 Controller Units
The micro-processor controller shall be built on plug-in cards, to allow on-line replacement service.
The power supply system shall be of a plug-in design.
The system will be of the dual (redundant) microprocessor design which will imply that both units will continuously update their databaese with latest field signals and operational parametrs.
Transfer from online unit to the redundant unit will take place by the system diagnostic program, user program or by manual interference.
Furthermore, each microprocessor controller will have:
- Error detecting/correcting memory with battery backup (except for non valotile memory)
- System diagnostics monitoring facilities for hard- and software failures, online alarming is included.
5.2.2 I/O Cards
The I/O processing cards shall directly communicate with the dual controller system.
The analog inputs shall be designrg with:
- Minimal 12 bit A/D conversion
- Common mode rejection factor, min. 120 dB (0-50Hz) at 100 Ohm line unbalance
- Total accuracy of min. 0.1% with power supply changes of +10 to - 15% and tmperature chargrs of ± 10OC.
The output cards will be as follows:
- All signals will have galvanic separation to the system and an over voltage protection up to 1 kV. In case of EX (i) signals, separation will take place outsids the systrm
- All I/O cards shall be designed for on-line replacement service and short circuit proof.
- Input cards
4÷20 mA/0÷10 V de :
- Field excitation supply 24 dc on terminals. Selection bridges for internal/external supply, resp.current/voltage. System input resistance < =100Ohm for current resp. min.1 Ohm for voltage
Pt-100 :
- 3 wire system, 0.1 C accuracy. Range per channel adjustable.Ex(i) via separate convertor with mA output
Thermo Elements :
- Use 4÷20mA/0÷10V dc input cards
Discrete Input :
- Excitation supply: 24V dc (from DCS system). LED status indication. Symmetric electrical circuit in relation to the field ground. Bridges for in/external supply. Adjustable 0÷10 m sec. filter against contract bounce
Frequency Signals :
- These signals may originate from turbine/PD meters.Frequency up to 2000 Hz. Pulse height 0÷10v to 20V p.p. Internal/external supply bridges (Pre-amplifier in meter)
Communication Port :
- RS 422 A channel, with galvanic separation
- Output Cards
4 - 20 mA - dc :
- Minimum 10bit D/A conversion. Burden maximum 700 Ohm. Selection bridges 4÷20/0÷20 mA. Fault detection monitor for: open circuit, output verification, system errors. These cards shall have provisions for connecting an auto/manual station.
- This station will allow for replacement of the card, while the field signals are frozen via the manual/auto and reverse shall be bumpless.
Contact :
- Potential free rating 24 V dc - 1 A, 240 V ac - 1 A
- Complete with spark suppression, LED status indication. Each channel shall be fused.
5.3 Operator Interface
The operator interface will consist of:
1. Operator stations
2. Printers
3. Engineering/supervisory console.
5.3.1 Operator Station
An operator console is defined as an assembly of devices wich permits the operator to perform whatever functions necessary to maintain control of process including start-up, shut down and response to abnormal situation.
Full color CRT displays with anti-glare screen and keyboards shall be the primary interface between the operator and the process. All CRT display shall be identical and be capable of performing all functions as stated hereafter.
The CRT display stations with tweir relevant keyboards shall be organized in such a way that sufficient redundancy of system components is provided. The failure of a single component shall not rezult in concidental loss of more than one operating station. The operator console shall be one of vendors standard consoles, built up-in modular sections with sufficient access facilities.
The number of CRT display/keyboard combinations shall be maximum three (3) per console.
5.3.2 CRT Display Package
The CRT data presentation shall be based upon a display hierarchy with each level being free selectable by the operator. As a minimum the following levels as discusses herein shall be included. Vendor shall summarize in his quotation any possible other display options and their relevant cost.
a. Plant overview
This display shall indicate alarms, deviation and control mode information.
b. Group display
The group display shall present information about a minimum of 8 tag numbers.
All variables within this group shall be detailed, the information presented shall include:
- Set point
- Process variables
- Alarm conditions
- Scale fectors
- Loop identification
- Output
- Auto/manual
- Local/remote/comp.
- Open/close
- Start/stop
The process variable and setpoint variable shall be in engineering units, the output value shall be 0-100% or 100-0% whichever required. A color change for a variable in alarm condition shall be presented on the group display. Selection of a loop within the group display by use of the keyboard shall allow the operator to adjust the set point, mode change and adjusting the controller output.
c. Detailed display
The detailed display shall indicate the information with respect to loop configuration, absolute value alarm limits, deviation alarm limits, controller settings, etc.
d. Trend display
The trend display (graphical) shall indicate a minimum of two (2) variables at a selectable time base. This feature includes real time trending as well as historic trending. Vendor shall clearly define all trending capabilities such as maximum duration and resolution of the proposed system in his quotation as options with their relevant costs.
e. Graphic display
The graphic display shall indicate pictorial sections of the plant including “live” presentation of process control and status information. Status indicates will include open or close indication of remote (DCS) operated valves, pump running, etc. The maximum number of graphic displays together with the numbers of line update points shall be clearly specified in vendors qoutation.
f. DCS diagnostic and status displays
The DCS diagnostic and status displays shall indicate the DCS hardware status and any relevant faulty component, active system bus wire breakage, earthfault, etc.
g. Alarm summary display
The alarm summary display shall provide the operator with a summary of current alarms. This display shall include loop identification (tag number and description), type of alarm, time of occurrence, return to normal and the group number which contains the alarm. The operator shall be able to select and display alarm groups by use of the keyboard (this shall be possible from all operator stations). After acknowledgement of the alarm the CRT will indicate the group display. The variable in alarm shall be identified by change of color.
All alarms shall be acknowledge through a common acknowledge control on the DCS. In order to acknowledge alarms on separate annunciators (emergency alarms) vendor shall provide potential free contacts suitable for 24 V DC 5A.
All plant alarms shall be connected to the DCS for signalling and logging purposes. In cases where more than one alarm is associated with a single variable it shall be possible to specify each alarm separately via configuration.
The DCS design shall permit first-out sequencing of alarm function within each dedicated group of specified alarms.
Different alarm priority levels are required to allow selective alarm management.
Emergency alarms will be potential free contacts wired to the DCS from a dedicated emergency trip system. Emergency alarms are monitored by the DCS for display on the alarm summary pages and graphic displays.
Prewarn alarms are generated in the DCS system. On activation of a prewarned alarm (process & deviations alarms) the operator will take the necessary action to avoid the occurrence of a dangerous situation. Prewarn alarms are processed in the same way as an emgency alarm, however, a clear discrimination shall be provided on the graphic display between emergency and prewarn alarms.
Hardware/system alarms are also generated in the DCS.
The hardware/system alarms shall include:
- Type and location of faulty unit
- Nature of malfunction
- Redundant unit in use
- Less of historical trend keeping
- Status of all devices connected to the redudant network system
- Fan failure
- Bad input range alarms
- Power supply failures.
5.3.3 Audible Alarms
Audible alarms shall be activated in case of process alarms (emergency or prewarn), hardware and system alarms, separate audible alarms shall be provided inside the DCS using different frequencies for each type of alarm.
5.3.4 Hardwired Pushbuttons and Switches
These devices are to be included in the operator console and wired to a separate terminal row installed inside the operator console.
5.3.5 Records (optional)
Conventional electronic strip chart recorders shall be provided as part of the operator console. Vendor shall specify in his quotation the make and type of recorder and shall list the available chart speed option.
a. Trend recorders (optional)
As a minimum six (6) variables shall be recordable in a trend fashion. Each recorder point shall be free assignable without regard to display grouping of the variable. The assignment of a variable shall be possible without the use of a keylock or password. Chart speed shall be user selectable. In addition an amount of dedicated variables will be permanently recorded independent from the DCS System (hard wired) and for dedicated hard wired recording.
b. Hardwired pen recorders (optional)
These recorders shall be standard convantional electronic recorders equipped with (3) pens. The chart size shall be four (4) inch nominal. The chart speed for all recorders shall be one inch per hour nominal. The number of 3 pen recorders required for each console is six (6) per console.
5.3.6 Floppy Disk Drives
The operator consoles shall be provided with a sufficient amount of floppy disk drives for configuration loading/storing and for storing and copying of data. As an alternative vendor may quote other devices suitable for this task (e.g. tape streamers, etc.).
5.3.7 Printers
Each operator station shall be equiped with one printer for alarm messages and one for reporting and logging.
The vendor shall provide assemblies that are suitable for a control room environment and will generate minimum noise during operation. The minimum printing speed shall be 240 lines per minute, 132 characters per line.
5.3.8 Miscellaneous Equipment
The console shall be designed that ample space is available to allow for installation of miscellaneous equipment at a later stage.
6. System Software
6.1 General
Besides the necessary basic operating systems, vendor will supply the following main functional packages shall be written in a common language to obtain fast down loading using preferably standard IBM PC/XT/AT or comatible computer x systems.
6.2 Controller
Data-base builder/editor.
6.3 Operator Station
- System configurator (vendor to advise)
- Group/loop display package
- Interactive graphics design package
- History and current trend data collection/display package
- Alarm display/handler
- Group alarm display
- System status display
- System diagnostics
- Operator tracking log.
Note: All system software shall be supplied in the latset version at delivery.
6.4 Data Base Builder/Editor
This package will have all the standard control algoritms available, e.g. :
Feedback control Squere root extraction
Feedforward control Thermocouple lineariz
Adaptive control Input signal cond. conversion to engineering units
PID algorithm Computational algorithms
Function generator Alarm routines
Cascade control Setpoint and output ramping
On/off control Integrator
First order filter Manual loading
Absolute values Mass flow algorithm
Ratio/bias control Tracking (Output, setpoint)
Time proportional control Dead time compensation
Signal selection Ratio control
Averaging velocity limiter Lead/lag compensation
Signal limiting/clamping Logic: and/or/nand/nor/xor
Logical Interaction with counter timer, flip/flop, one shot, arithmetic
function latch falling/rising edge Self tuning PID
(+, -, x, , , Ln, Log, floating point) Chromatograph PID block with sample triggering A/M switching
Analog input
Analog output
Frequency input
Frequency output
Discrete input
Discrete output
The DI signals shall be recognized within 1000 msec. duration time.
Vendor shall specify the available minimum/maximum times.
Load Factor
Based, upon an average 0.5 second scan/execution time and a predominant analogue control software, Vendor shall specify the number of I/0 signals (AI, AO,DI/DO), which can be handled with 50% loading factor. The vendor shall also specify in case of a combined analog and sequence control the specific loading capacity in relation to the level of complexity.
A sample of the used calculations method shall be attached.
6.5 Sequence Logic/Batch Language
This package will allow for free programmable sequential logic as well as batch structured programs and has direct data base access.
The language shall be based on Fortran, Pascal or “C” and allow for custom made applications. The package will reside as an extra layer on top of the control package in the controllers memory.
6.6 Operator Display Package
6.6.1 Trending
Any variable present in the data base shall be selectable for “software” trending.
There will be:
- Real time and historical trending and
- Single and multi-trend displays.
Real time trending is meant as a continuously updated trendline starting from now until the end of the screen.
The time base is dependent on the specified sample rate, which can vary from 1-900 seconds. The single trend graph will show the tag name, engineering units on the Y and time on the X-axis.
A background grid will help the operator readings. The real time trend date will reside in the memory. The min. number of real time trending signals will be 200. The resolution will be ca. 200 samples/signal/display.
Multi-trending shall be positive with up to 4 signals per graph. Each signal with its text, etc. shall have a separate color.
Option:
An adjustable cursor line will give an extract reading of the value in the graph.
Historical Trending is meant as data written to the disk, which is automatically updated. The time frame is not limited to the maximum number of samples per screen, but only to the size of the disk. The resolution can range from 10 seconds - 10 minutes averages with optional maximum and minimum value storage.
The data files per tag no. can be arranged in days and will be stored under the same tag no. and date. The data files shall be transparent to the user. A file editor will allow for correction on the system engineering level.
The operator can recall the historical trend by the tag no and the date and time.
In addition a time window scrolling and time compression, averaging function shall be available.
The trend display shall handle 1-4 signals with the same time base. The shefting of one signal over a part of the screen shall be possible. Full screen or split screen display shall be possible.
The range scale (“y” axis) shall have an adjustable zero and span per tag. The length of the historical files shall be selectable.
The system shall have alarming provisions for approaching overflows of the files. The system engineer might copy the files to a separate disk/tape and clean-up the remaining files. Ignoring the alarm will cause the system to overwrite the oldest data.
6.6.2 Interactive Graphics
The graphics will consist of a free configurable display updated with real time information from the current database and operator acces point.
The display will be constructed with a separate menu driven program.
A standard library with process and instrument symbols shall be available. The library shall be user extendable with special symbols/figures. The number of colors shall be minimum 8 foreground and 8 background.
The package shall have the following functionality:
- Color change of lines and symbols upon variables with min. 2 levels
- Flashing of symbols upon variables
- Filling of “vessels” by continuous color change
- Present controller data
- Operator selection of loops, with access to set point (A/M) etc.
- Paging to previous/next graphic
- Direct access to graphics via the annunciator/key pad
- Direct access to the coupled graphics from the loop/group display.
The total number of variables per graphic shall be minimal 50.
The presentation time including the minimum of 50 variables shall be less than 3 seconds. Loop/group displays will be presented within 2 seconds.
Stepping through pages will be instantaneous.
Graphics shall be memory resident or available on disk.
7. Application Software and Configuration
7.1 General
The vendor shall be responsible for all DCS application implementation such as but not limited to:
- Configuration
- Application software
- Sequence/logic programs
- Graphic building.
Vendor shall quote for this configuration software based up-on the specified configuration information. The vendor shall also quote for unit prices for the configuration that in case of changes they can be used as an add-on. during the engineering phase, the vendor shall have a system engineer and general consulting assistant available.
7.2 Configuration Information
Engineering contractor will use a complete set of the following documents:
- Engineering flow diagrams
- Sets of instrument schedule
- Interlock descriptions (see notes)
- Program flow charts (see notes)
Notes:
1. Interlock descriptions or program flow charts will be issued depending on the complexity of theproject and if project contains complex analog and/or logic control or sequence/batch control. In case above mentioned documents can not be issued at the inquiry stage vendor shall base his quotation up-on his past experience and the following information.
2. The discrete logic will have an approximate depth of (_______) discrete inputs and 1 discrete output with a functionality of approximately (_______) software generated conditions.
Total estimated number of I/) signals:
( ) Analog inputs (AI)
( ) Analog output (AO)
( ) Digital input (DI)
( ) Digital output (DO)
Total estimated number of control functions:
( ) Pid loops
( ) Cascaded pid loops
( ) Multi loop systems
( ) Analogue monitoring only
( ) Alarm or status monitoring only (DI)
( ) Motor start/stop/run circuits (1 DO, 1 DI)
( ) On/off valves with 2 position switches (1 DO, 2 DI)
( ) Sequence programs (Average _______ steps)
( ) Logic control functions (see note 2).
7.3 Custom Graphics
Estimated number of graphics: ( _______ )
The custom graphic generation shall be based up-on the engeneering flow diagrams issued. The number and detail of the interactive graphic shall be determined depending on the following factors:
( ) System graphic capabilities
( ) Display screen density
( ) Number of process areas
( ) Number of dynamic points per process area
( ) Operability
( ) Color selection for static and dynamic fields.
After receipt of specification of required graphic details the Vendor shall issue his proposal for comments/approval after which final implementation can follow.
8. System Services
8.1 Documentation
8.1.1 Approval of Documents
All drawings and engineering documents are subject to approval by purchaser. The vendor should not commence manufacturing before written approval of purchaser has been obtained.
8.1.2 At Quotation
- General system layout drawings - copies.
- Standard system documentation - copies.
- System power/grounding requirements - copies.
- Recommended spare parts lists - copies.
8.1.3 After Order
The vendor shall furnish the following documentation/drawings ____________ weeks after order for approval:
- Cabinet outline drawings
- Internal layout of all cabinets, card arrangement drawings, strapping, wiring, etc.
- Input/Output card arrangements
- System cabling
- Power supply cabling
- Grounding details
- Wiring diagrams and schematics.
Vendor shall supply a dedicated set of drawings for this project, complete with tag numbers, customers name and purchase order no. of equipment to be assigned. All dimensions on drawings shall be metric. Number of copies required:
- For approval : Reproducible copies
- Final : Reproducible copies
Documentation Manuals
Number of copies required: __________
- Harware maintenance manual
- Hardware referance manual
- Diagnostic tests
- Operating system manual
- Engineering manual
- Operating manual.
Custom software/configuration documentation
Number of copies required: _________
- Application software manuals/documentation
- Custom software listings
- Database listings.
8.2 Training
The vendor shall provide and maintain formal training programs on software system application and maintenance of the system described here in. Vendor shall inform/advise:
- Price per person (with minimum/maximum number of persons)
- Prequalification
- Duration in weeks
- Language
- Location
- Available dates.
8.3 System Testing
8.3.1 General
Detailed system testing procedures and costs shall be quoted in the quotation.
8.3.2 Factory Acceptance Test
Vendor shall inform client 10 working days in advance of the planned test dates.
The complete test shall be executed at vendor’s works.
The test shall be done in accordance with and by all parties approved test procedure manual.
The test will consist of:
1. Visual inspection
2. Burn in and duration test
3. Hardware test
4. Software test
5. Stating test.
In case of failures the test on subject items shall be repeated.
Burn in and duration test
The objective of the test is to prove that all components are burnt-in to a point on the flat part of the “bath tub curve”.
Each system shall be subjected to a 100 hour burn-in test, cycling between 20º C and 60º C with a fully operational system.
A temperature chart shall be provided by the vendor.
All defects occurring during the burn-in period and all repairs carried out shall be listed on a “burn-in events list”.
After a defect is repaired the burn-in cycle shall start over again.
Hardware test
The hardware test will contain all I/O cards, power supplies, CRT’s, communication links, foreign equipment communication links, system cabling, I/O terminations and miscellaneous equipment, etc.
Software test
The softwre test will be done on all system and application software, data base builder, editor, graphics builder, powerfail states, system diagnostics, automatic restart after power failure, alarm, trend, logs, etc.
All alarm settings, controller, computation and advanced control functions will be verified.
Stating test
The test will include a 100% “loop test” complete with I/O measurements and sensor simulation (using a loop simulatior, Volt/Amp. meter, freq., generator, etc.).
The vendor shall provide all necessary test equipment. The test equipment shall have a recent taes certificate. The test equipment shall comply with the following specifications:
Digital Volt/Amp. meter : accuracy 0.002% of the reading 1 digit = 0.004 mV
Precision Resistors : 0.01%
Resistor 5 decade bank : min. step 0.01 ohm stable switches.
mV source : 0.004 mV
Current source : 0.02%
Cold junction reference source : 0.5º C
Square wave generator : 0.02% duty cycle
The purchaser reserves the right to comment and modify the types and quantity of vendors test equipment.
8.3.3 Site Acceptance Test
After the successful factory acceptance test the system will be transported to clients site and installed by others under supervision of the vendor.
After installation completion, the vendor will check all external cabling and power-up of the system.
The final site acceptance test will then commence. This test will be a condensed from of the factory acceptance test (10% spot check).
8.4 Start-up Assistance
Start-up assistance if required shall be part of a separate order Vendor is required to supply hourly rates with his quotation for hard- and software field engineers.
8.5 Maintenance Contract
Vendor shall quote the following types of maintenance contracts:
1. Maintenance period: 1, 3 or 5 years.
2. 8 hours a day, 4 hours response time, standard working days with a price per call-out. 24 hours a day, 4 hours response time, for 365 days a year.
3. Use of client spares, including repairs. Vendor supply of spare parts from stock within 8 hours.
4. In addition any vendor’s standard contract.
8.6 Spare Parts
Vendor shall separately quote for the necessary spare parts of the total system, including items supplied by sub-vendor’s.
8.7 Warrantee
Vendor shall include a one year free of charge warrantee on hardware and system software failures for supplied and installed equipment. Standarting time is defined as the signed field acceptance test date by Client.
8.8 Transportation
The complete transportation freom the vendor to clients control room, including unloadeding will be vendors responsibility. The transportation and insurance costs shall be included in the quotation.