Dcs Specifications DCNB

INSTRUMENTATION SPECIFICATION
Zeppelin System India Pvt. Ltd., DCS SYSTEM

Vadodara
DOC NO : 3021-IN-SPC-001A CLIENT : AARTI INDUSTRIES LIMITED SHEET 1 of 30
PROJECT NO : 3021 PROJECT : BASIC & DETAIL ENGINNERING FOR 2.5 DCNB PLANT REV 7
SPECIFICATION FOR DCS SYSTEM
DOCUMENT NO. : 3021-IN-SPC-001A
7 08-01-2020 REVISED AS PER CLIENT'S COMMENTS AYM DRS BAP

4 27-04-2019 REVISED AS PER CLIENT'S COMMENTS MLP DRS BAP
1 10-12-2018 REVISED AS PER CLIENT'S COMMENTS IN MEETING MLP DRS BAP
0 06/12/18 ISSUED FOR REVIEW MLP DRS BAP
REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

BY BY BY
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SR. NO. DESCRIPTION PAGE NO.
1.0 PURPOSE 3
2.0 ENVIRONMENTAL CONDITIONS 3
3.0 CONTROL PHILOSOPHY 3
4.0 GENERAL SCOPE 4
5.0 DESIGN CONSIDERATIONS 6
6.0 DCS SYSTEM CONFIGURATION & FUNCTIONAL SPECIFICATIONS 10
7.0 BOUGHT OUT ITEMS INCLUDED IN DCS SUPPLIER'S SCOPE OF SUPPLY 22
8.0 TESTING AND ACCEPTANCE 23
9.0 INSTALLATION, TESTING AND COMMISSIONING 24
10.0 FINAL ACCEPTANCE AND WARRANTY 26
11.0 TRAINING 27
12.0 SPARES PHILOSOPHY AND CONSUMABLES 28
13.0 AMC FOR NON-COMPREHENSIVE/COMPREHENSIVE 28
14.0 DOCUMENTATION 29
15.0 SHIPPING 29
16.0 SUMMARY OF I / O COUNT ESTIMATION 30
ATTACHMENT :
A DCS SYSTEM ARCHITECTURE for 2.5 DCNB plant ( Dwg. No. :3021-IN-SPC-001 SHT. 01/01 )
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1.0 PURPOSE :
1.1 The purpose of this specification is to define the minimum requirements of a Distributed Control System (DCS) designed
for reliable, effective and optimum control and monitoring of a following process plant under execution. The control
system design shall be safe, simple to maintain & operate,relaible flexible to accommodate to changes in technology
and operating requirements, flexible to provide expansion during 15 years of plant life. This specifications shall be read in
conjunction with the I/O requirements mentioned in Annexure and the attached sketch showing the suggested system
architecture of the system for DCNB plant, Aarti Industries Ltd,Jhagadia,
Project details :
Name of client : Aarti Industries Ltd,Jhagadia,, BHARUCH
Project Name : 2.5 DCNB plant
Location : Jhagadia, Dist : Bharuch, Gujarat
2.0 ENVIRONMENTAL CONDITIONS :
Following environmental conditions shall be applicable :

2.1 Site Conditions (Applicable to all field mounted enclosures and storage)
Ambient temperature min / max. : 5 / 48⁰ C
Relative humidity min / max. : 80 / 95% Rh (Non-condensing)
Area classification : Hazardous, Zone 2, Gr. IIA IIB, T3
2.2 Control Room

Temperature (with AC operating) : 22-25⁰C
Relative humidity : 50 / 70%
Area classification : Non hazardous
In the event of AC failure the temperature inside the control room and relative humidity levels equal to, the figures given
in 2.1 above. The DCS hardware shall be designed to withstand these harsh conditions continuously without any
degradation of performance.
3.0 CONTROL PHILOSOPHY :
3.1 The plant DCNB shall be controlled by separate independent DCS system. All the process interlocks shall be realized
in DCS system only. A separate dedicated emergency shutdown system(Safety Instrumented System (SIS) ) is
considered for shutdown/trip interlocks. The DCS system , I/O system panels ,all marshalling panels/Termination panels
with safety barriers and relays, PDB panel ( if separately required )and all system hardware accessories shall be located
in DCNB panel room. All these panels size/make/model shall be 800/1200mm (W) x 800mm (D) x 2100mm (H) RITTAL
make with RAL7035 color shade.
3.2 There shall be min. 3 nos. of operator stations for operator, each of them shall have Dual 24” LED monitor. There shall
be one Engineering Cum operator station with single 24” LED monitor for programming & development and for
operation. Each of these operator station shall be independent of engineering station, i.e. in absence of engineering
stations also these shall present the plant’s real time data and control/monitoring facility to both operators.One no. A4
printer is to be considered and to be accommodated in control room. Separate engineering station for programming
development is considered for ESD system(supplied by other)
3.3 The DCS operator interface shall be the primary integrated window for operation of the control and safeguarding systems
and shall provide access to:
a Process control
b Sequence control status
c Equipment status
d Alarm overview
e Trip status overview -Override status
f Real-time trending
g Historical data trending
3.4 The system shall be 100% fault tolerant and dual redundant,except the redundancy at I/O cards levels
(if not specified).This means, all central control processors, all communication processors and all other central rack and
individual node’s common cards, all the communication cards, networks and cables, power supplies, etc. shall be 100%
fault tolerant and dual redundant
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3.5 Complete system hardware/software and communication load shall not exceed 50% system load even after the complete
implementation of project and running at peak load. This includes redundant control processor load also
3.6 Basic regulatory control provides closed loop control functions for stable and safe operation around steady points of
operation. The basic control functions comprise mainly of flow, level, pressure, temperature and analyser control loops
required as a minimum to operate and control the process. These loops may also include extended regulatory control
functions such as: split range control, override control, ratio control, cascade control. They may also include control
based on calculated variables, such as heat duty control, pressure compensated temperature control, etc. All of these
shall be realized in the central DCS system only
3.7 Monitoring comprises all Human Machine Interface (HMI) functions provided to those responsible for monitoring and
control of the process and it’s environment. These include alarm and monitoring displays, group and detail displays,
custom graphic displays, data historisation and retrieval, reporting, etc.
3.8 All Sequence controls, interlock and logic shall be realized in central DCS to provide automatic performing of tasks, such
as, opening and closing of valves, pumps, etc. - in a defined sequence.
3.9 There will be Uninterruptible Power Supplies (UPS) to provide backup power to all components of the control system,
including controllers, I/O, HMI’s, network components,Field instruments etc for cetrailsed DCS system in main control
room.
3.10 All operator stations shall be OPC (Open platform Communication) compliant. The minimum requirement of OPC is to
transfer minimum 4000 tag per second to client application in real time mode, without affecting operator
3.11 The systems shall be supplied complete with all application and operating system software's. The application program
shall also include software for performing functions like system development / modifications, program modifications, utility
programs, documentation etc. One set of licensed system software's including application software's shall be supplied
for DCS system.
3.12 The central cabinet room layout and local control room layout shall be sized in such a way that there shall be min. 1800
mm space between two consecutive rows of panels/cabinet and between panel and wall. All DCS and other control
systems’ Panel shall be openable from front and back side. There shall be panel segregation for various I/Os meant for
DCS system.
3.13 Various vendor packages may utilize PLC systems which will communicate with the main DCS system as detailed further
in this document.
3.14 System shall support various Hourly/Shift/Daily/Monthly Reports/Logs, Totalizes reports, SNAP shot reports, etc. in
Microsoft excel format only. The layout and type of reports/data, nos. of tags per report, etc. shall be as per owner’s
requirement. All engineering stations shall be equipped with MS Office license copy. System shall support min. 500 tag
historian software at 1 second interval
3.15 Complete system hardware shall be certified for ISA G3 class or G2 class corrosion level protection and shall be
compatible with various RFI/EMI immunity as per IEC.
3.16 The system shall support all various type of control/interlock/sequence algorithm and shall also support various high level
programming language like Functional block diagrams and SFC (sequential function chart) in real time control
application, in addition to standard control algorithms available in the DCS
3.17 Plant control room shall be provided with HVAC, Ventilation and air conditioning as well as false flooring (with min. depth
of 600 mm) and false ceiling
3.18 Historian orLong Term Data Archive Software on Engineering Station is to be considered with 5000 tags to get
process data and batch data, if any for 5 years with sampling time 1-5 seconds.
4.0 GENERAL SCOPE :
4.1 This specification defines the minimum requirements of system design including hardware & software, configuration,
manufacture, engineering, programming, inspection and testing, documentation, shipping, supervision of installation &
commissioning of Distributed control system (DCS). This shall include as a minimum.
a Manufacture, procure, supply, testing, installation supervision , handling and commissioning of all equipments and
accessories as required.
b Building of all operator interface, screen displays, database and reports.

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c System Hardware & Software configuration.
d FAT & SAT of all hardware / software and system integration testing with ESD system( supplied by others)
e Supply, supervision of Installation, testing and commissioning of marshalling racks, system cabinets and consoles/
printers including cables, terminals, IS barriers, power supplies and cubicle internal mountings. Supply of all system as
well as control room furniture as per ergonomic and Owner requirements.
f Proving of DCS system functionality as per requirements.
g Training of Owner's personnel at factory and at site on functional, operational, maintenance and programming aspects of
the system.
h Supply of complete technical and as built documentation in electronic form as well as hardcopy.
i Supply of all software on CDs / Pen drives along with required software licenses.
4.2 Supplier shall be completely responsible to supply all required materials and services for satisfying the
functional/operational requirements stated in this specification and its attachments / annexure.
4.3 The detailed scope of work, specific job requirements, exclusions, deviations, additions etc shall be indicated in the
material requisition and job specification.
4.4 Where any conflict exists between this specification and other job specification, the Owner shall be consulted. Vendor
shall not deviate from this specification without prior approval from the Owner.
4.5 Following matrix will explain about the scope of work and division of responsibilities between various agencies :
4.5.1 Engineering
Sr, No. Description V O C
1 Detail Engineering of the complete system including bought out items X X
2 System programming and configuration X
3 Generation of tag database X
4 Preparation & Implementation of Logic interlocks, sequences. X X
5 Implementation of advance controls X X
6 Configuration of various displays X
7 Generation of history database and reports X X
8 Generation of logging reports and other management information reports X X
9 Integrated Factory Acceptance Test (FAT) X W
10 Preparation of loop drawings X
11 Preparation of as-built drawings X
12 Power supply distribution drawing with power consumption statement X
13 Heat load calculation statement with power calculation X
14 Preparation of Panel wiring drawing with field termination details X
4.5.2 Supply and Inspection

Sr, No. Description V O C
1 Supply of all system hardware, software, etc. X
2 Supply of all bought out hardware X
3 Supply of all communication and interconnecting cables between different cabinets X
4 Supply of power supply cables from power Distribution Board (PDB) to all DCS
X
consumers
5 Supply of cables for Safety & System Grounding X
6 Supply of conduits for communication cables (if applicable) X
7 Supply of other erection hardware/consumables like ferrules, lugs, Fuses (diff size/rating), X
connectors for comm. cable, Terminals, MCB etc. as required for system
8 Inspection of all hardware / software, bought out items, cables, erection materials, X W
etc.
9 Packing and forwarding X
10 Transport to site X
11 Supply of Commissioning spares, Mandatory spares X
If any of the agreed point come into notice which is not as per specs at any stage of the project, Vendor has to comply it
immediately and shall be free of cost implications.
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4.5.3 Erection and Commissioning

Sr, No. Description V O C E
1 Unloading of system at site and shifting to site stores S X
2 Transport of system from site stores to actual location/s S X
3 Unpacking the system and inspection of the same for damages W W X
4 Fabrication of base frames for cabinet / console mounting S X
5 Installation of system at site S S X
6 Laying and termination of all cables from plant upto Marshalling Racks S S X
7 Laying and termination of power supply cables from UPS / other sources upto S S
X
Power Distribution Cabinets
8 Laying and termination of interconnecting power supply / signal cables between S X
cabinets
9 Laying and termination of communication cables and prefabricated system cables X X
10 Laying and termination of all earthing cables from respective bus bars to cabinets S X
within control room
11 System power up, loading of configuration, application software X
12 Internal loop / logic and interlock checking from marshalling racks upto operator X X X
stations
Integrated Site Acceptance Test including Simulation Test and Dry Run trial of
13 X W
Entire Logic, Water trial of all phases and Sequences and Handover of the System
14 Providing assistance for Plant commissioning X X
15 Termination & testing of of OFC cable with required accessories X
List of abbreviations
V : Vendor (DCS Supplier) O : Owner (AIL.) C : Consultant/PMC (Zeppelin)
E : Erection Contractor appointed by Owner
X : Primary responsibility W : Witness S : Supervision only
5.0 DESIGN CONSIDERATIONS :
5.1 General
5.1.1 This DCS system shall be of latest evolutionary type with ‘Open System Architecture’ having networking capability with
other systems distributed geographically in the various units of a plant over a plant wide information network such as
Ethernet / Profinet or other industrially recognized open network.
5.1.2 All components of the system shall be able to operate satisfactorily from 10°C to 40°C and 40% to 95% non-condensing
humidity.
5.1.3 The system shall be of modular construction and expandable in future by adding modules. The type of modules shall be
kept to the minimum possible in order to have interchangeability and low inventory.
5.1.4 The system software shall be governed by the operating system running in a real time mode and shall be able to meet all
specified functional requirements as a minimum. Any other standard / special software package, if available shall also be
offered describing the full capabilities.
5.1.5 The system shall be upward compatible i.e. new enhancements can be incorporated in the system for future up
gradation. Software & Hardware should be of Latest version. Windows 10 will be updated on when released from DCS
vendor without cost implication.
5.1.6 Vendor shall not quote any product / item which has become obsolete or going to be obsolete in next 10 years time.
5.1.7 Software updates/ patches to fix bugs / rectify defects for the same version of the software supplied to ensure uptime and
running of the system during warranty period or minimum 18 months time.Vendor shall confirm that service support of
the supplied product / items shall be offered for at least 10 years from date of commissioning. Vendor shall guarantee the
availability of replacement spares for this period. This guarantee shall also include all third party equipment supplied by
vendor along with his system.
5.1.8 Each channel is optically isolated from the system and factory tested to 1500 VDC for all field signals. Current limiting is
provided for each channel to protect against transmitter wiring short circuits.any fault on one channel will not affect the
performance / functioning of other channels
5.1.9 All the equipment covered in this specification shall be located in general purpose non hazardous area, normally in
control room. All control room mounted Panels shall be weather proof to IP-42.
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5.1.10 Flame Proof &intrinsically safe transmitters and E/P positioners shall be used if located in hazardous area. All solenoid
valves & Limit Switches shall be flameproof type. Suitable relays shall be provided for Isolation of digital inputs and
outputs.Suitable Isolators for Namur type level switches( Tunning fork type) of make P&F shall be considered .
5.1.11 For authorization level with password security system
Operator
Supervisory
Engineering
For hierarchical control system

The overall control system shall be structured to function in a hierarchical fashion, consisting of regulatory control,
sequence control and advanced control.
The regulatory control level and sequence control level will form the foundation of the overall system with the advanced
control level added above (when required)
The regulatory and sequence control must be capable of functioning without the advanced control.
5.2 Hardware Requirements
5.2.1 The DCS and all the subsystems shall be able to withstand the storage conditions as per 2.1 for long periods atleast 6
months.
5.2.2 The system shall have a high MTBF value, high availability of 99.99% and shall have a proven track record of continuous
successful operation in a chemical plant for a minimum period of two years. DCS Supplier shall submit letters from end
users to prove the above criterion. No prototype hardware / software of any nature shall be supplied.
5.2.3 The system shall be designed "fault tolerant" by selecting components of proven quality and by proper design.
Redundancy shall be provided as a minimum as per requirements given later in this document to improve reliability and
availability.
5.2.4 All electronic components / modules for controllers, I/O subsystem and communication interfaces shall be conformally
coated so as to have a high corrosion resistance. The DCS Supplier shall clearly state the corrosion protection class G3
or G2 as per ANSI / ISA S71.04, to which the coating conforms to (No indigenous coating is acceptable).
5.2.5 On-line replacement of any module shall be possible (i.e. removal and addition of a module without de-energizing the
system). There shall be no interruption in the system functioning while replacing a faulty module on-line.
5.2.6 The system shall be protected from static electric / magnetic fields as well as against commonly occurring EMI and RFI
due to walkie-talkie sets, mobile phones, pagers, operation of relays or contactors carrying heavy currents, etc. EMI / RFI
protection shall be as per latest IEEE / SAMA standards.
5.2.7 Volatile memory shall be protected with battery back-up. Alarm annunciation shall be provided for low voltage of the
battery on screen .
5.3 Software Requirements
5.3.1 The operator and engineering stations shall be with Windows 10 Operating System latest version. If offered Operating
System is Wndow 7 then vendor to update windows 10 on when released from DCS vendor without cost implication.
Antivirus softwares shall be installed to guard the operating system against external virus attacks. Licensed MS office
for engineering station shall be included
5.3.2 System shall have extensive self diagnostic software routines capable of locating and identifying faults at least up to
module level and display of the same in detailed diagnostic displays.
5.3.3 The system shall have in built ready-made software to detect open sensors and bad process values with an alarm. This
facility shall be available for analog and digital outputs as well.
5.3.4 Self tuning feature shall be available as a standard. It shall be possible to download on-line, parameters computed by the
software either manually or automatically. The process shall not get disturbed when a loop is being tuned.
5.3.5 Database shall be global. It shall reside preferably at one point in the system and available to any node on the network.
Data addressing shall be by using tag name and not physical or logical address.
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5.3.6 Dynamic data shall be updated in all the operator stations simultaneously. Any configuration changes made in the system
shall be downloaded to all the concerned stations simultaneously and without any manual intervention, transparent to the
user.
5.3.7 The system shall support a powerful and easy to use graphic builder package. This shall include commonly used tools
like cut and paste, object embedding etc. Drawing tools commonly found in CAD like midpoint of line, centre of circle,
draw tangent, fill / unfill an object, duplicate an object, zoom object, shall be supported. Package shall have extensive
library of symbols for equipment, piping components and instruments.
5.3.8 Alarm management features supported by the system shall include alarm prioritising (at least 5 levels); alarm sorting /
filtering on priority, time span, plant unit, frequency of occurrence, etc. It shall be possible to deactivate nuisance /
secondary alarms. It shall be possible to organise alarm data in a browser view to analyse the same as per user's
requirements. Dead band shall be configurable individually for each alarm (not loop wise).
5.3.9 Control builder package of Engineering station shall support all the languages commended by IEC 61131 standard.
Configuration of loops shall be achieved using standard pre-configured program blocks and linking the same. Commonly
available tools in "MS WINDOWS"® like drag and drop, copy / paste, hyperlink, shall be available to make the tasks
simpler and faster. On line help shall be available, just a mouse click away, in the form of tips, explanations, examples,
etc. Facility to enter users comments (non-intelligent data) shall be available for ease of understanding.
5.3.10 The system bulk memory shall be sized assuming all analog and digital inputs/outputs to be trended at a sampling rate of
1 minute for a duration of 60 days. Data archival shall be supported. It shall be possible to archive old data automatically
after a certain defined time period on to a storage media (DVD/Hard disk, etc.) from which it can be viewed on-line for
analysis
5.3.11 System shall have extensive self documentation tools. It shall be possible to import in to the system / export from the
system, tag database, in a easy to use format like "MS EXCEL"® or "MS ACCESS"®. Similarly it shall be possible to take
print-outs of generated logic, loops and sequences in any of the languages specified by IEC 61131. In case this is not a
standard feature of the system, necessary additional software shall be offered to comply with these requirements.
5.3.12 Sequential control software is required to control the sequential operation of various plant items which involves a
number of steps, in which on-off valves are opened and closed with their positions continuously monitored and
equipment is brought up to load and reverted to standby.
5.3.13 Dynamic display of generated loops, logic, sequences, shall be possible. It shall be possible to read raw data, results of
intermediate computations in a dynamic form.
5.3.14 On line changes in configuration of loop / logic /sequence shall be possible. Whenever a part of configuration is changed
the outputs (analog or digital) pertaining only to that part of existing configuration shall be in 'hold' mode (held to last
state). The rest of the configuration and outputs shall remain unaffected. When the downloading of configuration changes
is complete, the controller shall take over the execution of the loop / logic as per the new configuration. This shall also
apply to those cases when tag numbers are added / deleted from a data base.
5.3.15 The system shall boot itself automatically on total power failure. This shall be a procedureless operation without any
intervention by the operator or engineer whatsoever. During power failure, all the digital outputs / controller outputs shall
go to zero state, and all controllers shall fall back to manual mode. On restoration of supply the system shall be ready to
receive instructions from the operator without the requirement of any system software files to be loaded , the controllers
shall remain in manual mode with outputs at zero, and digital outputs shall assume their states as dictated by the logic /
5.3.16 Forcing of digital outputs shall be possible through Simulation software of Operator Station. This shall be password
protected. Whenever a output is bypassed, an alarm shall be generated. A separate dedicated alarm summary shall
highlight all the outputs under bypassed state.
5.3.17 Similarly facility to bypass Digital input shall be available through password protection. Whenever the input is bypassed
and bypassing any interlocks/alarms pop up window generated on graphics with alarm.
5.3.18 License Report Package software shall be considered

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5.4 Redundancy Requirements :
5.4.1 Hardware /software Redundancy requirements at various levels are as follows:

Controller CPU and memory : 1:1 Redundant
CPU communication interface with I/O : 1:1 Redundant
Power supply to controller CPU & I/O Racks : 1:1 Redundant
CPU communication interface with system data highway : 1:1 Redundant
Profibus/Ethernet Communication (IOs to Controllers) - DCS 1:1 Redundant
5.4.2 The redundant system shall be designed such that, on failure, automatic bump less changeover to the other unit shall
take place. The processor system shall have automatic control transfer switching, which shall transfer the entire
configuration and data base of failed processor to the back-up processor. Design must ensure that data integrity is
maintained during switch over and no portion of data to be transferred is corrupted before and during switch over to the
back-up processor. It shall also be possible to replace and test the failed unit without disrupting the control of the process
bump less changeover to the other unit shall take place.
5.5 System sizing / loading criteria
5.5.1 The vendor shall submit calculation and basis of determining the availability of equipments and architecture of the system
to meet all the requirements in this specification and at the same time observe the maximum loading indicated. Loading
here is referred to the use of memory, CPU time and communication capacity. The loading shall consider the worst case
of high system activity. After the completion of commissioning maximum loading on various subsystems shall be as
follows :-
a 60% : Processor including memory

b 60% : Communication Processor & Communication network
( The maximum number of nodes in network shall not exceed 70% of maximum capacity.)
c 60% : Power supply for system & Bulk Power supply
5.5.2 I/O Count Provided in summary of I/O list is already inclusive of 30% installed spare. The installed Spares will be
Complete with Terminal Boards, prefab Cable including Barriers/Relays as required and completely wired upto TB.
5.5.3 The DCS system shall be designed such that after the completion of commissioning the DCS system the following
evenly distributed spare capacity shall be available.
Spare space : 30% usable spare space for installing I/O module of each type in system cabinet,
Marshalling Racks & in PDB panel in future.
5.5.4 The system shall be designed with capacity of physical tags license for minimum 4000 tags of list of I/O's (including
spare) given excluding IMCC soft tags. Vendor to confirm capacity of the offered controllers in terms of physical tags.
5.6 Power supply distribution
5.6.1 Power Supply Levels

The different power supply levels used shall be as follows :
Uninterruptible Power Supply (UPS) : 230 V AC (±10%) 50 Hz (± 2 %) UPS
Standard (non-UPS) power supply : 240 V AC, 50 Hz
DC Power Supply : 24 V DC
Note-1 Each power supply output failure relay output to be taken in DCS for alarms.
5.6.2 The DC supply as above shall be derived by the Supplier from the UPS by providing two or more regulated SMPS
(Phoneix make) in parallel redundant configuration. Any other power supply required by the Supplier shall be distributed
by him form the UPS / DC power supply.
5.6.3 The distribution of power to different plant loads at various voltage levels shall be as per the following table:
Sr. No. Type of Load Supply Type

1 DCS, printers, separately powered instruments, 230V AC, UPS
2 Panel lighting / Socket outlets / Panel fans / Console lighting-fans 240V AC, Non-UPS
3 2 Wire transmitters, relays , safety barriers ,isolators, etc. 24V DC UPS
4 4 wire transmitters , Solenoid valves Analyser etc. 230V AC, UPS
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5.6.4 For 4 Wire Transmitters Double Pole MCBs (Apprx. 30 Nos.) shall be considered . All 4 wire Transmitters are based on
230VAC Power Supply Only. All MCB's shall be located in PDB Panel/Marshalling cabinet.
6.0 DCS SYSTEM CONFIGURATION & FUNCTIONAL SPECIFICATIONS :
6.1 System components
6.1.1 Basic system configuration shall be as per Job specifications and system architecture drawing attached, however the
system shall consist of the following major sub-systems :
a Processor system
b I/O system
c Communication system
d Operator interface system
e Engineer interface system
f Open System Connectivity
g Power Supplies for system & Bulk power supply
6.2 Functional requirements
6.2.1 The system as a minimum, shall meet the following requirements without the supervisory computer :
a Control
b Data acquisition and monitoring
c Alarming
d Logging and report generation including Batch report generation
e Historical data storage
f Trending
g System shall have free memory space available for the user and CPU shall have additional capability to perform
advanced control functions, process optimization programs or generate management reports as specified in job
specification.
h Plant process interlocks and safety shutdown shall be performed in DCS system. PLC for package units shall be
connected with DCS communication system.
6.3 Processor system
6.3.1 The control function of the system shall be executed by microprocessor based single or multi-loop controller consisting of
I/O ports and a set of algorithms which are easily configurable.
6.3.2 This system shall be capable of executing following control functions and set of algorithms as a minimum :
a General : Monitoring and alarms

b Control : P, PI, PID, adaptive gain, ratio, cascade, feed forward, etc
c Arithmetic : Addition, subtraction, multiplication, division, averaging, square root, ramp, rate of rise / fall, etc.
d Linearization :Flow pressure / temperature compensation, linearization, polynomial etc.
e Dynamic : Lead / Lag, dead time, timer, etc.
f Modes : Auto , Manual , Cascade.
g Limiter : Low Limiter, High Limiter, set point.
h Comparator : Less than, greater than etc.
i Selector : Low, High, etc.
j Logic : AND, OR, NOR, NOT, XOR, Start / Stop, etc.
k Miscellaneous: Direct/reverse output, Anti-reset windup, slow fast ramping of set point & output etc.
l Flow tantalization and mass & energy balance calculation.
6.3.3 The processor shall be able to scan close loop and open loop in less than 500msec ,Interlock logic 250 msec &
Historization shall be 1 sec.
a The scan time of all type of analog/digital input/output cards & DCS algorithm (Scan time means the sum of total time
required for reading an input, running control algorithm and writing the output values) shall be better than the required
scan time of the fastest running control/closed loop.
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6.3.4 The controller shall be able to operate in either manual, auto, cascade mode. Mode change-over in either direction shall
be procedure-less and bump-less. It shall be possible to change set-point, tuning constant, operating mode, control loop
configuration from the central level i.e. operator’s interface keyboard and engineer’s interface keyboard.
6.3.5 The size of the memory shall be sufficient for storage of the program instruction required by the control schemes. Offer
shall indicate the amount of memory occupied by the actual program and spare capacity available for later program
modifications or additions. A minimum of 20% spare memory space shall be provided at the time of handover of the
system to owner.
6.3.6 Memory shall be non-volatile. However, in case volatile memory is provided, battery backup shall be provided for a
minimum of 3 days time to keep the stored program intact. A battery drain indication shall be provided before the battery
gets drained.
6.3.7 Watchdog timer shall be a software device. The healthiness of processors shall be continuously monitored by watchdog
timer. Any hardware or software problem in the processor system including CPU, memory, power supply, communication
interface etc shall cause the watchdog timer to report processor failure.
6.3.8 Loop integrity shall be maintained in processor system architecture by providing one to one processor back-up. In case
failure is detected in the active processor all the loops of the failed processor shall be transferred to the back-up
processor. Loop integrity shall also be applicable to I/O system, power supply modules and any other device associated
with the processor system.
6.3.9 While downloading any changes, made to a particular tag, from engineer interface system to the processor system the
controller output shall be maintained at its last value and should not be driven to zero value even momentarily.
6.4 I/O System
6.4.1 The I/O system shall be capable of accepting process signals from various process sensors and switches preferably
without requiring external or auxiliary signal conditioning devices. The system inputs shall include 4-20 mA
DC,Resistance temperature detector (RTD) and discrete inputs as a minimum apart from others as specified in the job
specifications. It shall be capable of processing linear and non-linear analog inputs, providing square root extraction for
flow signals, linearization. The system shall be able to generate 4-20 mA DC current signals for analog outputs and
potential free contacts for the discrete outputs as a minimum apart from others as specified in the job specification.
6.4.2 No. of inputs per Inputs/output (I/O) module shall not exceed either of the following :-
a Analog I/O Modules : 8/16 channels

b Discrete I/O Modules : 32/64 channels
6.4.3 Each I/O shall be galvanically/optically isolated from external control circuit by suitable means. The minimum isolation
level between I/O and logic circuit shall be 1000 volts DC.
6.4.4 Each I/O shall be protected against the reversal of polarity of the signal. Reversal of polarity on I/O termination shall be
indicated in DCS.
6.4.5 Each digital I/O module shall have a LED status indication. The channel wise status indication shall be provided as soft
display on the screen. Digital input modules shall be suitable for proximity switches intrinsically safe namur type and
field switches with potential free contacts.
6.4.6 Each input shall be provided with filters to filter out any noise in the input line and contact bouncing noise.
6.4.7 All the inputs shall preferably be double ended i.e. two wires per input and not with common return for all inputs.
6.4.8 IO Modules shall be with facility to force particular value during failure of module or data highway or bus.This to keep
particular interlock to take it's action if condition signal fail due to module fault or bus fault of that particular
module.Input/output set as predifined.
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6.4.9 The interrogation voltage to the input / output contact shall be powered from separate power supply / supplies and shall
not be a part of I/O module unless otherwise specified. The redundant power supply shall be considered so that the
redundancy is maintained at all levels.
6.4.10 Output contacts shall be potential free/dry contacts. Wet contacts / powered contacts / TTL outputs etc. shall not be
acceptable. Vendor must provide arc suppression device for each output contact. Each output shall be short-circuit proof
and protected by fuse. Visual indication of fuse down must be provided for each output.
6.4.11 All I/O modules shall have facility to detect wire open condition whenever normally open inputs ( close on alarms ) are
considered.
6.4.12 I/O terminals - shall have terminals Phoenix make for terminating the field I/O 's. All field inputs shall have one fuse
terminal phoenix make with LED indication
6.4.13 The analog outputs shall be 4 to 20 mA DC unless otherwise specified. Each channel shall have current limiting such that
effect of short circuit in one channel does not have operation of other channels and current does not exceed 30 mA.
6.4.14 All 4-20 mA inputs shall be capable of being software configurable on an individual channel basis to provide energizing
power for a 2-wire transmitter or to receive powered signal from an external device such as 4-wire transmitter. The 2-wire
option shall be capable of driving the transmitters plus an additional load of 600 ohms such as that imposed by a local
indicator.
6.5 Operator interface system (Qty-3 nos in main control room)
6.5.1 The operator interface system (OS) shall perform the function of Human Machine Interface and provide the centralized
information to the plant operator / Engineer. Following data shall be available on OS :
a Indication of all analog and digital process variables of control loops, open loops and all loop related parameters.
b Manipulation of control loops including changing set point, mode, output, configuration, running and computational
constants.
c Alarm displays and annunciation.
d Graphic displays and status indication.
e Logging and trending including historical trend recording
f Self diagnostic messages, operator messages
6.5.2 Operator interface system shall consist of operator consoles. 3 Numbers of operator consoles shall depend upon the size
and operating philosophy of the plant and indicated in job specifications. The consoles shall be with keyboards ,
individual or common electronics, logging printer , hard copy unit, Console shall be Flat type fabricated from CRCA
sheet(1.6mm) with color rittal grey included with cooling fan & temp monitoring facility & alarm on DCS as a minimum.
Console shall be metallic closed type with Dual monitor shall be 24" LED type table top. 4 Nos. operator chairs
(Revolving Type) and one printer table shall be in vendor scope.
6.5.3 All the functions and displays of operator consoles shall be full interchangeable. In general each console shall be
dedicated a particular area of the plant, however it should be able to take the functionally of other consoles, if required.
6.5.4 The real time clock of each operator console shall be crystal controlled one which shall be independent of line frequency.
All the real time clocks in the system shall be synchronized with each other.
6.5.5 Each console shall be an industrial type metallic, closed console with front & back side double doors and with high
resolution table top Dual monitor 24"-OWS ,capable of displaying alpha-numeric & graphic displays. Multiple colours
shall be used to distinguish parameters such as control, information, process and alarms etc.The display screen shall be
able to display the full alpha numeric tag number of a process variable. A minimum of twelve (12) digits shall be provided
for the tag number and 24 digits for the process description, unless otherwise indicated in Job specifications.
6.5.6 Data display update rate shall not be more than one (1) seconds. Cursor control devices must be available with each
console like keyboard & mouse.
6.5.7 Keyboard shall be normal QWERTY PC keyboard. It shall be easy to operate and shall meet all the functions to
configure, operate and maintain the system. A conversational user friendly software shall be used for operation,
configuration and maintenance of system. The key board shall not be susceptible to dust and moisture. It shall be
provided with key-lock facility to prevent any un-intentional program modification.
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6.5.8 The operator, as a minimum shall be able to access following through key board :
a Selection of all the displays including the direct selection of loop in alarm page turning facility, overview, group view and
loop view selection etc.
b Selection of loop for operation.
c To acknowledge alarms as and when they are annunciated on the operator console.
d Facility to enter any changed parameter like set point, manipulated variable digital commands and to cancel any wrong
entry while making such change.
e Facility for easy positioning of cursor for the selection of any parameter.
f Selection of hardcopy printout, logging printout, alarm history, printout and assignable trend recorder points.
g Auto / Manual / cascade mode changeover of each Processor.
6.5.9 Each OS shall be PC based, standalone type, with its own power supply, Dual monitor, CPU and memory,
communication interface, keyboard, and mouse.
6.5.10 Each OS shall have the following specifications:

i PC type : Workstation grade
ii CPU : Intel Xeon Processor 3.2 Ghz,or as per mfr std
iii Display : 24" LED Monitor X 2 (Dual Monitor)
iv RAM : 8 GB DDR4
v HDD : 500GB X 2
vi CD/DVD, read / write drive : Required
viii Graphic Card : 2 X NVIDIA Quadro K620 2GB Graphics Card.
ix Communication interface with data highway : Redundant
x Mouse : Optical
xi Keyboard : Shall be normal QWERTY PC keyboard
xii Anti virus software package : License software
xiii Operating System : Windows 10 Professional
6.5.11 The OS shall provide following process displays :
6.5.11.1 Overview display
a Overview display shall incorporate a minimum of 128 analog or discrete inputs which can be monitored simultaneously on
the screen (referred as page). Each page shall be organized into a suitable number of groups. Each groups shall be
identified separately. Each group shall further incorporate suitable number of inputs (referred as tags). Suitable
identification and description shall be shown for each group on the overview display to relate it to a group or loop display.
b All analog points in the overview shall be represented as variable lengths indicating deviation above or below the normal
operating value or set point.
c Alarms shall be displayed in change of colour against each variable if the variable crosses a set value. Control loops
operating in manual mode shall be indicated. All input in alarm condition shall be identified by flashing.
6.5.11.2 Group Display
6.5.11.2.1 Group display shall be limited to the group of inputs as displayed in the overview display. Each group shall preferable
include eight (8) numbers of inputs. Each input in the group shall be identified by the tag number, unit of measurements
and process description which shall be displayed on the screen. Display, as a minimum shall show the following degree
of details :-
a Process variable in analog form shall show as a percentage of the transmitter span on a linear scale bar graph of 0-
100% or engineering units and in digital form as alphanumeric display in engineering units.
b Set point value in analog form as a percentage of the transmitter span on linear scale barograph of 0-100% engineering
units and in digital form as alpha-numeric display in engineering units.
c Output value in analog form as a percentage of linear scale bar graph of 0-100% and digital form as percentage.
d Processor mode i.e. auto, manual, cascade.
e Process alarm on process variable, deviation.

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f Selected loop within the group shall be identified by cursor marking or similar identification.
g Control valve failure position.
h The contact input / output shall be represented by simulated graphic lamps and configurable alpha-numeric status
description.
i Also It shall be possible to control the process from group views. Following control actions shall be possible.
i) Increase / decrease of set point value either slow or fast.

ii) Change of Processor mode i.e. Auto / Manual transfer.
iii) Changing output to the final control element.
iv) For digital points, start/stop or open / close command.
6.5.11.3 Loop Display
6.5.11.3.1 Loop display shall provide a separate detailed display for each of the process inputs. The graphic representation of
analog and digital points shall be similar to group display. However, in addition following information shall also be
presented in alpha-numeric form as a minimum.
a Processor tuning constants.

b Process variable zero and span values.
c Alarm set point on various parameters.
d Limits on set point, output
e Processor action (Direction / Reverse)
f Failure position of final control element.
g Computational constants like ration or bias.
h Integrated value.
i Output to the final control elements
j Engineering units.
k It shall be possible to change tuning constant, scale, zero & span, limits on set points, output, control mode start / stop
command through the keyboard of operator console, although some functions shall be restricted through key-lock
control.
6.5.11.4 Graphic Display.
a It shall be possible to display dynamic graphic of different section of plant on the operator console 24” LED. Graphic
displays shall be field configurable only through engineering key-board with standard / user defined graphic symbols.
Different plant sections dynamics shall be displayed on different pages.
b The system shall have the capability of having and developing graphic symbol library as per ISA-5.1 and 5.3. In addition,
standard industrial symbols like distillation columns, heat exchangers, pumps, compressors, tanks etc shall also be
provided as a standard.
c Graphic displays shall be interactive type through which it shall be possible to control the process. It shall also be
possible to send motor start/stop and shutdown valve open/close command, as specified in job specification from this
display.
d It shall be possible to view the process variable and alarm points and view and change set point value, manipulated
variable, Processor mode etc from the graphic display. Also compressor/pump status and valve status shall be displayed
on the graphic display with different colours.
e Various colours used in the generation of graphics like colour of the process lines utility lines, instrument signal lines and
event modifier conditions shall be finalized during detailed engineering.
f It shall be possible to go from any graphic page to related graphic pages or any group view or alarm summary in single
key stroke using soft key function.
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6.5.11.5 Trend Display
The system shall be capable of displaying the following trends :
a Real time trends of the parameters as specified in job specifications displaying current data. However, it shall be possible
to assign any parameter for real time trend.
b Historical trend for number of parameters as specified in the job specification. However it shall be possible to assign any
parameter for historical trending.
c Historical data shall be stored on the nonvolatile memory device like hard disc in such a way that such historical data can
be utilized for archival storage and subsequent recall.
d Real time and historical trend shall be possible on any parameter or variable like measured variable, set point, output,
calculated variable etc.
e It shall be possible to sample and store data of instantaneous and average value at the intervals mentioned below.
However it shall be possible to display by scrolling or expanding the time base for all the trends.
i) At interval 2 second and below for the real time trend.

ii) At 1 minute, 10 minute, 30mins, and 1hour interval for historical trend.
f Historical data trends shall be displayed for a period of minimum up to 25 hours for a data sampling rate of 1 minute.
g Fast trend requirement, (trends with sample time faster than Real time trend) if any shall be specified in the job
specification.
h Selection of the tag number and sampling time for real time and historical trending shall be possible from operator
keyboard.
i The system shall also have a multithread capability in such a way that it shall be able to display set point, measured
variable and output on the same display, the trend of either the same process variable or any other process variable.
j Trend display shall be single line type or bar graph type with additional information like loop tag number, engineering
units, span, present value of the trended point. Alarm status etc displayed.
6.5.11.6 Alarm Display
a It shall be possible to display process as well as system alarms on the operator console for operator’s attention and
action. Alarms shall appear immediately on the operator console as and when they occur on priority basis.
b It shall be possible to set process alarm limits from the engineering keyboard i.e. alarm limits on absolute value of
measured variable, rate of change of measured variable, high and low deviation set points, high, extra-high, low and
extra-low points on process variable and output etc. In addition, it shall be possible to derive alarm conditions on the
basis of few calculations performed by the system.
c Alarm messages shall be displayed by flashing the page and group number of the input under alarm irrespective of type
of display. It shall be possible to access the group or tag in alarm condition with a maximum of two key-strokes of
operator’s console keyboard. The plant overview display, in addition to display alarm message shall also be able to
provide warning by changing colour of excessive deviation of process variable from their set value.
d All alarms shall be displayed as and when they occur or generated with change in the colour of display in the following
sequence, activating an audio signal :
i) Continuous flashing - Un-acknowledged alarm

ii) Steady display - Acknowledged alarm
e The system shall not put off the audio alarm and visual flashing even after the condition returns to normal unless it is
acknowledged by the operator.
f It shall be possible to display summary of all alarms in the sequence of their occurrence and shall disappear from display
only when they are acknowledged and cleared. The alarm display shall list the following for each alarm as a minimum.
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i) The date and time of occurrence

ii) Point identification (i.e. Tag numbers)
iii) Point description
iv) Type of alarm (absolute value of deviation)
v) Serial number of alarm in the sequence of its occurrence.
g The history of alarm conditions shall be maintained in the data base for alarm history display and printed on shift-wise
basis for the parameters specified in the job specifications. The alarm display and print out shall list the following for each
alarm as a minimum.
i) The data and time of occurrence

ii) Point identification (i.e. Tag number)
iii) Point description
iv) Type of alarm (absolute value or deviations)
v) Time of acknowledgement
vi) Time of return to normal
vii) Serial number of alarm in the sequence of occurrence
6.5.11.7 Configuration display
a Configuration display shall provide a separate detailed display for each loop indicating the configuration of the loop.
When control requires more than one loop, all interrelated loops shall also be displayed. Following information is required
to be available for configuration display.
i) Loop configuration giving designation of each blow.

ii) Control block interconnection showing soft wiring or hardwiring
iii) Value of each blow parameter like P&ID, ratio, bias, dead-time, lead-time etc.
b It shall be possible to configure & reconfigure the loops from this view using user friendly software.
6.5.11.8 OS Logging feature
a It shall be possible to log all measured and computed parameters,operator actions alarms etc.from operator consoles.
b Logs shall be required on hourly, shift wise (8 hourly) and daily basis and some cases for weekly and monthly basis as
specified in job specification.
c All parameters required for logging shall be stored in memory in accordance with data base update rate. However it shall
be possible to perform basic arithmetic calculations such as averaging, summing , efficiency calculations etc prior to
logging.
d The log format shall be user definable, in general. However the typical log formats for hourly, daily and shift wise reports
shall be as defined in the job specifications. For extended logging like weekly and monthly reports, system shall have
capability of writing programs in high level language. High level language compiler software sufficient memory space and
necessary hardware shall be provided.
e Number of log reports shall be as per number of log formats defined like hourly report format, daily reports format etc.
Number of pages in each log report shall be sufficient to accommodate all the parameters for logging as defined in the
job specifications.
f Hourly report shall be printed only as and when initiated on demand by the operator and shall not be printed automatically
after the end of the hour. All other reports shall be printed automatically at the end of the pre-defined time as well as on
demand by the operator. The maximum storage time for a log information shall be 15 minutes after the pre-defined print
out time for a format, within which time log report must be printed. In case report could not be printed within the
scheduled defined time, data shall remain stored till the report is finally printed.
6.5.11.9 Logging Hardware
a Vendor to offer 1 no A4 network Laser printer black & white for Logging cum Alarming to be used for :-
i) Printing of hourly, shift-wise, daily and weekly log

ii) Shut down report printing
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iii) Any other report defined in the job specification

iv) Logging the process and system alarm messages as and when the occur.
v) Print the alarm history for every shift of operation or on demand from operator console
vi) Logging events such as operator actions as and when they are initiated.
vii) Alarms and Events shall be clearly distinguishable on the report, preferably by colour.
b Printers should be suitable for a control room environment and should generate a minimum noise during operation. The
printers shall be connected to the system network.
c Print out shall show as a minimum the tag number, description, data and time of occurrence, time of acknowledgement
and time of return to normal.
6.5.11.10 Self Diagnostics
a Following diagnostics shall be available as minimum
i) Analog input Diagnostic - Sensor out of range, open or shorted loop, analog to-digital converter check
ii) Analog Output diagnostics – Open or shorted loop
iii) Configuration diagnostics – Checking compatibility and availability of selected I/O hardware & software
iv) Memory diagnostic – Checksum , Parity etc
v) CPU / Memory diagnostics – O/p of processor from an algorithm checked against pre-stored answer
vi) Power diagnostics – Monitor availability of supply voltages
b The self diagnostic message for a system failure shall appear on the operator console irrespective of display selected.
The choice of the detailed self diagnostic displays shall be made by a key-lock switch.
c The system shall have an extensive set of self-diagnostic routines which shall locate and identify the system failure at
least up to module level including redundant components.
d Failure of a system shall be annunciated with the change in colour. To aid system maintenance and for effective fault
location, following display shall be provided as a minimum.
i) Communication system status display

The display shall show an over view of different sub-systems connected over the communication system showing status
of each system. When a failure is detected by the system self diagnostic routing, the display shall indicate the location
and nature of malfunction.
ii) Systems diagnostic display

One display page shall be available for each system which can be called on demand. The same shall display as
minimum system number and type, error code and description and details of failed module.
6.5.11.11 Data Storage, Archival and Retrieval
a Historical data shall be stored on a non-volatile memory device like hard disc which can be subsequently recalled by
operator on any screen. System must support multiple historical data discs in order to avoid data loss in case of disc
crash. One operator station shall have historical trend facility for minimum 90 days with minimum 1 sec capture time .
Facility shall be there for other time sampling also from 1 minute / 5 minutes also) other operator station shall have
storage of report package for minimum 30 days
6.6 Engineer interface system( qty - 1no)
6.6.1 Engineer interface system shall be primarily an engineer’s interface which shall normally be used for configuring, tuning
and maintenance of the Distributed Control System. This shall consist of a console provided with one operator cum
engineering keyboard. Exact number of such consoles will be as per Job specification.
6.6.2 Engineering console shall have as a minimum the same capability as operator console. All the plant operations as
specified under operator console shall also be available on Engineering console.
6.6.3 It shall be possible to perform all system configuration functions from the Engineering console typically.
a Data base configuration including overview, group, loop, multiloop and multivariable control configuration.
b Group or multi-group alarm inhibit from the plant under maintenance.
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c Configuration or re-configuration of alarm settings, their values, addition or deletion of any control block or components in
a loop.
d Tuning of control loops like changing, PID, dead time values
e Compilation of graphic displays
f Setting of real time clock
g Compilation of logs/reports/historical trend points.
h To call detailed self diagnostic displays for maintenance aid.
6.6.4 Tuning of a control loop shall be possible from engineering as well as from operator console, the location shall be
selected by the operator using a “Tuning mode” key-lock switch provided on the operator console. In tuning mode it shall
be possible to operate only the loop under tuning from engineering console. In case of simultaneous commands from
operator and engineering consoles, operator console shall over-ride.
6.6.5 During the normal operation, the engineering console, in no case shall interfere with the process operation or system
software. However, any change in the configuration shall be down loaded into the system with proper knowledge of the
operator.
6.6.6 All detailed diagnostics of the system shall appear on the engineering console with a print out on the configuration and
maintenance (C & M) printer. A common diagnostic message on the operator console shall indicate the need of the
maintenance. C & M printer shall be used for printing the configuration or configuration changes, printing system alarms
as and when they appear and to print out any engineers command from engineering console and event printing.
6.6.7 ES shall be PC based, standalone type, with its own power supply, display screen, CPU and memory, communication
interface, keyboard, and mouse.
ES shall have the following specifications:

i PC type : Workstation grade
ii CPU : Intel Xeon Processor 3.2 Ghz,or as per mfr std
iii Display : 24" LED Monitor
iv RAM : 16 GB DDR4
v HDD : 1TB X2( RAID -1 Configuration)
vi CD/DVD, read / write drive : Required
viii Graphic Card : 2 X NVIDIA Quadro K620 2GB Graphics Card.
ix Communication interface with data highway : Redundant
x Mouse : Optical
xi Keyboard : Shall be normal QWERTY PC keyboard
xii Anti virus software package : License software
xiii Operating System : Windows 10 Professional
6.7 Communication system
6.7.1 The communication system shall be a digital communication bus, that provides a high speed data transfer rapidly and
reliably between the operator consoles, process I/O devices, process computer and other devices connected to it.
6.7.2 Communication system shall be dual redundant, consisting of two separate communication buses and two separate
communication system interface for each device. In case of systems having traffic directors, redundant traffic directors
shall also be provided.
6.7.3 Communication speed on the communication bus shall be sufficient to update the operator console data base once in
every second. The overall system performance shall not be degraded whether communication system is 10% or 100%
loaded.
6.7.4 In case of main bus failure or any communication device failure, the transfer to the back up device or bus shall be
automatic without interrupting the system operation and without any operator’s intervention. Information about the failed
device/bus shall be displayed on the operator console. It shall be possible to connect or disconnect a device from the
system without disturbing the operation.
6.7.5 In general, the transmitting message shall identify the receiving device. The transmitting device shall receive a reply from
the receiving device on the receipt of correct message. Lack of response shall be considered as a receivers failure.
6.7.6 Vendor to offer optionally 3rd party communication module of three ports of Industrial Ethernet/Modbus communication
interface.Qty of third party communication module shall be frizzed after finalization of no of interface requirement.
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6.7.7 Vendor to consider Profibus/Profinet/Ethernet modules (approx. 8 Nos. considering total 320 nos drives/VFD's ) for
communication between DCS system and IMCC (supplied by others) . communication cable shall be in AIL scope apart
from that communication between IMCC and DCS shall be jointly done by DCS and IMCC vendors . DCS shall be able
to monitor, control metering and annunciation for all pump motors and VFD's as per mentioned in IMCC I/O list. All
7 hardware and software required for communication shall be considered. Configurations and monitoring shall be done
with coordination of IMCC vendor.
6.7.8 Historian server cum reporting (If required separatly.)

PC type : Workstation grade
CPU : Intel Core i7 ( Minimum)
Display : 24" LED monitor
RAM : 16 GB DDR4
HDD : 2TB with RAID 1 Configuration
CD/DVD, read / write drive : Required
USB ports : To be disabled
Mouse & KEYBOARD : Mouse-Optical & keyboard Shall be normal QWERTY PC keyboard
Anti virus software package : License software for three years
6.8 Open system connectivity
6.8.1 The system shall be capable of interfacing with other plant systems and computers over a well established
communication network like Ethernet conforming to IEEE 802.3
6.8.2 The system software shall be support industry standards like UNIX, Windows 7, OSF/MOTIF, TCP/IP and DDE, SQL etc
as applicable.
6.8.3 The method of data access by any user on this network shall be by I/O Tag name and not by any physical or logical
address.
6.8.4 Special attention shall be given to network security of the Open Control Systems Network. Firewall shall prevent
unauthorized access from the office network to the Open Control systems Network.
6.9 Panel/ Cabinets
6.9.1 These shall be used to mount the hardwares like the CPU and communication hardware, I/O modules ,safety barriers,
Relays ,termination etc.
6.9.2 Vendor to offer DCS Panel, Marshalling cabinet ,PDB Panel separately .The Panels / cabinets shall have 30% spare
space for future expansion including system card slots in I/O racks.
6.9.3 These shall be used to terminate all field cables and mount other hardware like signal conditioning cards, I/O termination
assemblies, safety barriers, signal converters, relays and any other equipment as required.
6.9.4 Panels shall be self standing type with hinged front/rear doors and lifting eyebolts. Hinges shall be concealed type. Door
handles shall be flush type. Cabinets shall be provided with doors locks. It shall be possible to open all the cabinets with
a single key.
6.9.5 100 mm channel base shall be provided at the bottom for mounting the cabinets with antivibration pad.
6.9.6 Dimensions (especially height and depth) and colour of all cabinets shall be identical from point of view of good
aesthetics. Dimensions and colour of cabinets shall be 1200/800 mm(W) x 800 mm(D) x 2100 mm(H) of RITTAL make
(color - RAL 7035 Pabble grey) with 100 mm black powder coated base frame.
6.9.7 Painting shall be oven baked (2 primer coats and 2 final coats) epoxy I powder coating, with matt finish.
6.9.8 Cable entry shall be from bottom through removable split gland plates. Sufficient space shall be left near the cable entry
area for proper glanding of field cables.
6.9.9 All wires shall be routed through covered PVC ducts. PVC ducts shall be sized liberally to ensure that future wiring can
be easily accommodated without the duct overflowing. Separate ducts shall be used for intrinsically safe (IS) and non-
intrinsically safe (NIS) circuits.
6.9.10 The system related cables shall be laid panel to panel only. No system cable will go panel Out & then IN. Cable duct &
space to be considered accordingly.
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6.9.11 Internal layout of marshalling cabinets shall ensure that there is no overcrowding of components and maintenance
accesses are properly provided. The empty slots shall be plugged with blind plates. Terminal strips shall be easily
accessible and ferrules readable. All components shall be provided on front and rear surfaces of the mounting plate. No
component shall be mounted on the sides/doors/gland plates or in the bolting space provided between the adjacent
cabinets.
6.9.12 A safety earth bus bar shall be provided in each cabinet for earthing. For shields of cables and system earth, separate
bus-bars shall be provided insulated from the cabinet structure. Material of all bus-bars shall be copper with
nickel/chromium plating. Separate tagging to be provided for earthing .
6.9.13 Cabinets and all the components mounted inside them shall be numbered with rear engraved acrylic / printed labels.
6.9.14 CFL/LED light fittings (230 VAC) with isolation and door switches shall be provided (one each in front and rear) for proper
illumination. Louvered openings with dust filters (5 micron) at the bottom of doors of cabinet shall be provided . A utility
switch/socket 240 VAC, 5A shall be provided. A common fuse shall be provided to protect against any short circuit.
6.9.15 Two nos of ventilation fans (240 VAC) with isolation in each cabinet shall be provided. Fan failure relay to be
considered.In case of failure of any fan, alarm should be generated on DCS. The cabinets shall also be provided with
Temperature monitoring which will generate alarm in case of high temperature. The readings of temperature of all
cabinets shall be available in DCS.
6.9.16 Incoming two pole MCB shall be provided for each power supply. Outlet of MCB 1 HRC fuse shall be terminated on bus
bars from which power to individual components shall be tapped through HRC fuse. For loads with very low power
consumption (viz. trip amplifiers, isolators) fused terminals shall be provided for isolation. Looping of wires for distribution
of power is not acceptable.
6.9.17 Each panel shall include 2 numbers of insulated bus bars for system ground, 2 numbers of non-insulated bus bars for
safety earth (1 type of each on either side).
6.9.18 The rear engraved acrylic labels (white letters on black background) shall be fixed in the cabinets with screws and not
pasted with the glue. Project name,PO number, type of panel, supplier and year of manufacturing shall be required in
packing of panel.
6.9.19 Quantity of marshalling racks shall be frozen only after final approval of layout drawings during detail engineering.
6.9.20 Wiring
6.9.20.1 Wiring shall be done using tinned copper PVC insulated multi stranded wires of 1.0mm2, 660 V grade Finolex make.
6.9.20.2 All wires shall be provided with hot stamped ferrules with black letters on white background. The ferruling philosophy shall
be self + cross. Wires shall be crimped with bootless lugs as per the cable size.
6.9.20.3 The cables for connection, in inter-panel / intra-panel which are bolted together, shall be flexible. If separate cabinets /
panels, then multi-pair cables shall be used.
6.9.20.4 The size and color coding for wires to be used within the cabinets is as follows :
Sr. Conductor Cross

Type of Signal Color Code
No. Section
1 4-20 mA, input / output 1.0 mm2 White(+)/Blue (-)
2 Digital Inputs 1.0 mm2 Grey (+) /Black (-)
3 Digital Outputs 1.5 mm2 Red(+) / Black (-)
4 RTD Inputs 1.5 mm2 White / Red / Red
As per load requirements
5 230 VAC Power Supply Red(P) / Black(N) / Green(E)
6 24 VDC Power Supply As per load requirements As above
7 Chassis earthing Yellow / Green
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6.9.21 Terminals
6.9.21.1 Terminals shall be single tier type. Multi-tier terminals shall not be used. Following specifications shall govern:
a Make : Phoenix
b Material : Melamine
c Size : 4 mm2. For power supply wiring the size shall be as per requirements
d Type : Screw less, side/side entry, 20% extra in each category, Fused 2.5 mm2 with LED indication for
digital outputs ; link type for analog inputs / outputs, standard type for others
6.9.21.2 Fused and link terminals shall be put in both the wires of the circuit. LED indications shall be provided for fuse failure.
Looping of terminals is not acceptable.
6.9.21.3 All field terminations shall be done on a terminal strip only and not directly on any other hardware
6.9.21.4 Terminal strip blocks shall be arranged as per JB termination (including spare cores / pairs) to achieve 1:1
correspondence with JB termination. No core shall be left unterminated . 30% spare terminals shall be supplied as spare.
JB number shall be affixed along with the terminal block number.
6.10 Other Miscellaneous Requirements
6.10.1 The internal layout of the marshalling cabinets shall be such that at site, after erection, only pre-fabricated cables need to
be laid from marshalling cabinets to system hardware cabinets; thus saving valuable time. To achieve this, the signal
conditioning hardware, relays, barriers, etc. shall be mounted in marshalling racks.
6.10.2 The different cabinets shall be used for different category of signals as —
a Analog Input / Output

b Digital inputs and Digital outputs I relays
6.10.3 All digital outputs and digital inputs shall be through interposing relays with LED indication
6.10.4 There shall be minimum 30% spare space in each marshalling cabinet after full implementation of project.
6.11 System Hardware Cabinets
6.11.1 These shall be used to mount the system hardware like the CPU and communication hardware, I/O modules etc. The
colour and dimensions shall be same as those of marshalling cabinets, except the dimensions as 800 mm(W) x 800
mm(D) x 2100 mm(H) can be offered as alternate. All other specifications remain identical to those of marshalling
cabinets given as per 6.9.
6.11.2 The system hardware cabinets shall have 10% spare space for future expansion including system card slots in I/O racks.
6.11.3 The quantity of system cabinets shall be frozen only after final approval of internal layout during detail engineering.
Cabinet shall be with front and Rear Mounting facility.
6.12 Cabling
6.12.1 Vendor shall supply and install all interconnecting cables which shall include but not limited to the following :
a Cabling between Marshalling racks , System cabinets , Barrier cabinets

b Cabling between Relay racks , Auxiliary consoles , System cabinets
c Power supply cabling to all system components from Power distribution cabinets
d Earthing cables of IS ground , Signal ground , cabinet body ground , system consoles , peripherals inside control room.
e Communication cabling
f Earthing cable from pit to cabinets.
g Profibus/Ethernet armoured cables for HMI to DCS system including supply of Profibus/ethernet connectors as
required .
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6.12.2 Interconnections shall preferably be done preferably with the help of pre-fabricated cables with plug-in connectors at both
ends.
6.12.3 All interconnecting cables shall be preferably armoured and laid in ducts / tray to protect from rodents. If unarmoured
cables are used , then these shall be suitably routed in flexible conduits. All system cables should be routed panel to
panel only, routed below false flooring is acceptable.Vendor to supply PVC conduit for all unarmoured communication
6.12.4 All the cable entries / exit shall be through bottom plate only with suitable glands.
6.12.5 Field cables from instruments / Junction boxes are excluded from Vendor’s scope of supply.
6.13 Earthing
6.13.1 Each panel cabinet console and other equipment in control room shall be provided with an earthing lug. All these lugs
shall be properly secured to the earthing bus as per the earthing philosophy indicated in design basis.
6.13.2 All circuit grounds of electronic instruments, shields and drain wires of signal cables shall be connected to instrument
ground bus which is electrically isolated from the AC mains earthing bus. This bus shall be typically 25 mm wide and 6
mm thick of copper. The instrument ground bus is connected to independent instrument system ground buses through
insulated wires.
6.13.3 Each panel shall be connected to earth pits through two parallel runs of cables
7.0 BOUGHT OUT ITEMS INCLUDED IN DCS SUPPLIER'S SCOPE OF SUPPLY :
7.1 Following items are included in scope of supply of the DCS Supplier. All these items shall have 20% installed spare
capacity. The makes of these items shall be strictly adhered to and concurrence of Owner / consultant shall be taken
before purchasing these from alternative sources. Owner / consultant reserve the right to reject / accept any supplier
suggested by the DCS Supplier. Model numbers of each item shall be frozen during detail engineering.
Sr.
Description Acceptable Makes Quantity Remarks
No.
1 Profibus/ethernet connectors P+F As reqd
2 Signal converters, if required ABB, Yokogawa As reqd
3 2 Pole rotary switch L&T, Crompton As reqd
4 HRC Fuses GE As reqd
5 Glass cartridge fuses Essen As reqd
Board mounted Relays with LED, 24
Omron
6 VDC coil, 2 changeover contacts of 5A As reqd
230VAC rating
7 MCBs double pole of different ratings Siemens As reqd
Redundant 24VDC power supply with
8 failure relay contact o/p & Oring diode Phoenix or Weidmuller As reqd
with failure relay contact o/p
9 Safety barriers P + F/MTL As reqd
9 Isolators for Namur type switches P + F/MTL As reqd
10 Wires / cables Lapp /Finolex As reqd
11 16-Port Industrial Managed Ethernet Cisco / Net gear /or equ. As reqd
12 Terminals (Fuse Terminals with LED) Phoenix As reqd
13 Table top Consoles for OS, ES Reputed 13 nos
14 Cabinets Rittal, As reqd
15 Chairs Godrej or equivalent 5 nos
16 A4 size Laser Printer , colour HP 1 no
Fiber Optic Cable, multimode 6 core, Digilink/Finolex or
17 1000 meter
armoured type equivalent manufacturer
18 FO Connectors Digilink or equivalent mfr. As reqd
19 LIU Box , Redundant Digilink or equivalent mfr. As reqd
20 FO to Ethernet convertor, Redundant Digilink or equivalent mfr. As reqd
21 FO Splicing Digilink or equivalent mfr. 1 lot
22 A3 size Laser Printer , black & white HP 1 no
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8.0 TESTING AND ACCEPTANCE :
8.1 General
8.1.1 On the basis of guidelines specified in this specification, vendor shall submit their own testing, installation, commissioning
and acceptance procedure. For hardware, the procedure shall include purpose of test, test definition of input, procedure,
results expected and acceptance criteria. For software, it shall include details of the method, list of test sequence of
execution, results expected and acceptance criteria.
8.1.2 The testing and acceptance of the system shall be carried out on the mutually agreed procedure and criteria based on
these guidelines and vendor standard procedures.
8.1.3 The owner reserves the right to be involved and satisfy himself at each and every stage of inspection. The owner shall be
free to request any specific test on any equipment considered necessary by him although not listed in this specification,
as a part of approval of factory testing procedure. The cost of performing all tests shall be borne by the vendor.
8.2 Factory acceptance test (FAT)
8.2.1 Vendor shall test and demonstrate the functional integrity of the system hardware and software. No material or equipment
shall be transported until all required tests are successfully completed and certified “Ready for Shipment” by the
owner/consultant.
8.2.2 Cost of inspection / testing shall be borne by the DCS Supplier.
8.2.3 It shall be vendor’s responsibility to modify and/or replace any hardware and modify the software if the specified functions
are not completely achieved satisfactorily during FAT.
8.2.4 The schedule for the FAT shall be included in the Vendor’s proposal. Factory acceptance test procedure shall be
submitted for approval at least 4 weeks before the FAT at vendor works.
8.2.5 Prior to inviting Owner / consultant for inspection of the system it is expected that DCS Supplier has completed all the in-
house QC checks on the system. This includes not only standard checks on hardware but also checks on bought out
components, complete application software, internal wiring, and so on. DCS Supplier shall confirm in writing that all the in-
house checks are complete and the system is ready for FAT.
8.2.6 The entire system shall be staged by the DCS Supplier in his works. The consoles and cabinets shall be assembled in
exactly the same way as they will be at site. All the interconnections between cabinets shall be complete, system
hardware shall be in place, all software loaded and bought-out hardware included in DCS Supplier's scope of supply duly
mounted. Wiring within each cabinet and between cabinets shall be complete.
8.2.7 Owner / consultant reserve the right to carry out inspection of any bought out items at the sub-supplier's works.
8.2.8 It shall be the responsibility of DCS Supplier to arrange all the test and measuring instruments required during inspection.
The instruments shall have a valid calibration certificate from a recognised test house and the calibration shall be
traceable to any of the national test houses.
8.2.9 The FAT includes connection of the Package PLC system with the DCS system and testing of the serial communication
with the DCS system. Package PLC Supplier shall jointly with DCS Supplier demonstrate functional integrity of the
system hardware and software.
8.2.10 Vendor shall test and demonstrate the functional integrity of the system hardware and software. No material or equipment
shall be transported until all required tests are successfully completed and certified “Ready for Shipment” by the
owner/consultant.
8.2.11 The inspection shall briefly envisage the following :
8.2.11.1 FAT includes integration & testing of the IMCC communication with DCS with the IMCC supplier at DCS FAT. DCS
vendor & AIL to co-ordinate with IMCC vendor that they should bring final required hardware with software & accessories
@ DCS vendor's site at the time of FAT.
8.2.11.2 FAT includes integration & testing of the ESD communication with DCS with the ESD supplier at DCS FAT. DCS vendor
& AIL to co-ordinate with ESD vendor that they should bring final required hardware with software & accessories @ DCS
vendor's site at the time of FAT.
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8.2.11.3 Hardware Inspection
This shall consist of:
a Checks on general workmanship like fabrication quality, paint quality, paint shade, etc.
b Dimensional inspection for base frame, height, depth, width, etc.
c Provision of bus bars for safety earth, system earth, IS earth
d Checks on correctness of all labels.
e Power supply wiring and operation checks for fans, tube lights, utility sockets, etc.
f Power supply and signal wiring checks including colour code of wires, size of wires, correctness of ferrules, correctness
of wiring termination, wiring segregation, etc.
g Provision of terminals of correct size and type
h Operation of lamps, push buttons/switches, MCCBs/MCBs, annunciators, relays/contactors, ammeters/voltmeters and
other instruments mounted on the consoles or cabinets.
i Megger test for power distribution cabinets
j Checks on correct installation of I/O racks as per approved drawings and I/O modules within racks as per nest loading
k Redundancy checks as per specifications on power supply, CPU , communication, and I/O modules.
l Checks on battery back-up on all volatile memory switching off power for the duration given in DCS Supplier's
specifications.
m Scan time as specified for all I/Os
n Performance check of individual modules wherever possible
8.2.11.4 Software Inspection
This shall consist of :
a 100% check on generated data base. This includes checks on correctness of tag number, service description, measuring
range, engineering units, input signal conditioning, control algorithms associated with the tag, output signal conditioning,
etc.
b Graphics shall be checked (100%) for static and dynamic information. This includes checks on correctness of graphics as
per process, line thickness and colour, correctness of equipment tags and instrument tags, units of measurement,
modifier conditions, linking between pages, operation of dynamic and interactive targets, etc.
c Operation of all keys on the keyboard for their proper operation.
d Printing operations like alarms, operator actions, log reports, etc
e Correctness of tag grouping in group displays and trend displays, sampling interval for trends. Alarm priorities.
f Logging operation
g Special (non-standard) loops shall be checked 100% from input to output for correctness of engineering
h 100% checks on all logics and sequences
i 100% Checks on any higher language programs.
j Communication between any third party device like Package PLC and DCS.
8.2.11.5 After hardware and software inspection is complete, an exhaustive punch list of all pending, incomplete jobs, mistakes,
etc. shall be prepared jointly by the Owner, consultant and DCS Supplier. DCS Supplier shall attend to all the punch list
points and certify in writing to that effect. Dispatch clearance shall be given only after such a written confirmation is
received.
8.2.11.6 Test Set-up Requirements
DCS Supplier shall make available the following testing apparatus / hardware during inspection. No inspection shall be
carried out unless the test set up is ready.
a Switch-bank of 64 switches, push buttons, duly wired; minimum 1 number.

b Lamp-bank of 64 lamps; minimum 1 number.
c 4-20 mA signal generators to simulate two wire and four wire transmitters, minimum 2 numbers.
d mV generators, decade resistance box; minimum one number of each.
e Pulse generator for testing pulse inputs.
9.0 INSTALLATION, TESTING AND COMMISSIONING :
9.1 Vendor shall offer the services of the installation team which would install the equipment in the control room, lay the
interconnecting cabling inside the control room, check out, test and commissioning the system.
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9.2 Vendor’s responsibility at site shall include all activities necessary to be performed to complete the job
including:
a Receipt of hardware/software and checking of completeness of supplies.
b Supervision of Installation of the supply equipment & interconnection cabling
c Checking of interconnection, hardware and software configuration, overall system functioning etc
d Loop checking (Internal loop / logic and interlock checking from marshalling racks upto operator stations)
e Commissioning and on-line debugging of the system.
f Performance of final acceptance test & Assistance in plant commissioning
9.3 Exclusion from DCS vendor’s responsibility shall include the following:
a All civil works in the control room including false flooring, control room lighting and air conditioning ducting.
b Laying and identification & termination of field cables ( in marshalling racks )
c Field instrument installation and calibration
d Installation of DCS system & Marshalling cabinets
9.4 Loop checking
9.4.1 Vendor shall be responsible for internal loop checking which shall also include checking of the interconnection, at control
room end, configuration and ensuring over all system functioning. For complete loop checking vendor will provide
assistance to Field contractor
9.4.2 Calibration and installation of field instruments, installation of junction boxes, interconnection between instruments and
junction boxes, laying of single, multi pair cables up to control room, tagging all field cables, performing continuity /
insulation test of cable, core identification of field cables etc. shall not be in the vendor scope. This work shall be carried
out by the field contractor.
9.4.3 Vendor’s scope of work, as a part of system installation and loop checking shall include checking termination of all field
cables in control room, checking of interconnection between instrument / equipment, ferruling and tagging of
interconnecting cables in control room, ferruling of field cables in control room and performing overall loop performance
check.
9.4.4 Loop checking shall be carried out to check the functional performance of all elements comprising the loop and thereby
ensuring proper configuration, functioning and interconnection.
9.4.5 Vendor shall coordinate with the field contractor for smooth and proper loop checking. Any discrepancy found during
checking shall be brought to the notice of Engineer-in-charge (PMC)'. Complete loop checking shall be performed in the
presence of the Engineer-in-charge or his authorized representative. All reading shall be recorded on a suitable format
which shall be handed over to the vendor by the field contractor after completing calibration record of each field device.
On the completion of loop checking, remaining information related to loop checking shall be filled by the vendor.
Completely filled format duly signed shall be submitted for approval, to Engineer-in-charge (PMC)'.
9.4.6 All the components of the loop shall be checked for proper functioning. All field instruments connected to control room
shall be loop checked at 0%, 50% and 100% of FS (for both increasing and decreasing signals). The input signals shall
be simulated using various simulator and applied from field after disconnecting the field cable connection.
9.4.7 Receiver alarm cards shall be checked by the vendor for different setting on both increasing and decreasing signals.
Shutdown schemes shall be checked for proper functioning, configuration and actuation.
9.4.8 Performance of individual loops may be accepted for an overall accuracy of + 1.0% unless otherwise specified. Where
deviation exists, recalibration of instruments, based on the scope of work, shall be carried out either by field contractor or
by vendor.
9.4.9 Signal from Processors/shutdown schemes to control valves/shutdown valves shall be checked at the respective valves.
The stroke checking including checking of time of operation of control valves/shutdown valves also forms a part of loop
checking. Vendor shall coordinate this activity with field contractor and record the same in the loop
checking format.
9.4.10 For the loop checking of loops connected to substation, vendor shall be responsible to coordinate with the Electrical
Contractor.
9.4.11 After loop checking is completed, vendor shall connect back any terminals and connections removed for loop checking.
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9.5 Site Acceptance Test (SAT)
9.5.1 The owner shall provisionally takeover the system from vendor after site acceptance test. Site acceptance test shall be
started only after the satisfactory performance of loop checking and verification of records by Engineer-in-charge.
9.5.2 The site acceptance test shall be carried out in the presence of owner representative and Engineer-in-charge (PMC)' or
his authorized representative.
9.5.3 Vendor shall carry out the following functional tests, as a part of site acceptance test as a minimum :-
a Hardware verification as per final bill of material.

b Visual and mechanical check-up for proper workmanship, identification, ferruling, nameplates etc.
c System configuration as per approved configuration diagram.
d Demonstration of all system diagnostics
e Checking of correct change-over of redundant devices
f Checking of proper functioning of all disc drives, alarm summary, printers etc.
9.7 Testing/Calibration Equipments
9.7.1 Vendor shall make available all consumable, instruments and equipments necessary for testing, calibration, maintenance
etc. as required by the defined scope of works. All instruments and equipments used for the above purpose shall be of
standard make with accuracy better than the accuracy expected from the calibrated/tested instruments, and certified by
National Physical Laboratory or other equivalent agencies. These instruments/equipments are necessary only during
testing/calibration/maintenance.
9.7.2 Vendor shall arrange for adequate number of test equipments like meggers , multimeters, CROs , 2-wire transmitter
simulators , thermocouple / RTD simulators etc as required. Also test equipment of adequate specifications to monitor
main system power supply from UPS shall be arranged by vendor to establish power quality before system is powered
ON.
9.8 Mobilization Schedule

9.8.1 Mobilization of DCS Supplier's manpower for carrying out erection and commissioning activities shall be as per the
following table:
Sr. Number Of Visits Duration Of

Activity Remarks
No. Expected Visit
All activities ike inspection of
hardware of system at site,
1 2
Supervision of installation,
Total 90 days
internal loop checking
Pre-commissioning ,SAT and
2 2
commissioning assistance
10.0 FINAL ACCEPTANCE AND WARRANTY :
10.1 Owner/consultant shall take over the system from DCS Supplier after final Site Acceptance Test (SAT) as given below
10..2 The integrated system shall run uninterruptedly for one week from the date of commissioning of the whole plant. Any loss
of time due to reasons like power failures, forced shutdowns of the plant, etc.; which are due to no fault of the DCS
Supplier shall also be counted as run time. Once the system failure is detected, However if any software / hardware
failure of the system occurs due to which the system or a part thereof has to be shutdown, the acceptance test of the
system shall start all over again from the beginning. During above period, any malfunctioning of the system components
shall be replaced / repaired as required free of cost. As soon as one week of uninterrupted run of the system is
completed successfully, the SAT is deemed to be complete.
10.3 DCS Supplier shall ensure hardware support (supply of spare parts) and software support (including periodic updated
software versions) for a minimum period of 10 years after commissioning.
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10.4 It shall be obligatory on the part of supplier to modify and/or replace any hardware and modify the operating, application
and diagnostic software free of cost, in case any malfunction is revealed even during on line operation after taking over
within the warranty period . Supplier shall also provide the total maintenance of the system during warranty period.
10.5 Warranty shall be inclusive of all systems supplied by DCS vendor inclusive of bought out items like bulk power supply,
barriers, UPS (if supplied), PCs,Panel accessories etc.
10.6 The warranty period shall be 18 months from Site acceptance Test of the system at site. During warranty period Vendor
shall make good all failed components of any part of the System and depute his service engineer to site if required free to
cost.
11.0 TRAINING :
The DCS Supplier shall train process engineers, operating and instrument maintenance staff in his works & at site. It is
envisaged that the following activities are covered :
11.1 Maintenance Training
This shall cover the following topics minimum :

• System architecture
• Hardware & Functions of each subsystem
• Procedures for loading different software.
• Complete application software. This shall cover everything from basics like generation of the different system nodes,
building of displays, loop and logic building, advanced language programming, debugging of developed application etc.
• Commonly occurring hardware / software problems and the way to fix the same.
• Diagnostic routines available; their use and interpretations.
• Routine preventive maintenance procedures.
11.2 Operations Staff Training
This shall be restricted to operation of the system and cover the following topics minimum :
• System architecture
• Functions of each subsystem
• Function of each key in the keyboard, various shortcuts.
• Generation of various displays.
• Display hierarchy, access methods for various displays, switching between different displays.
• Control of plant from various displays.
• Alarm handling
• Logging software
11.3 Training Requirements
Training requirements shall be as per following table.

Sr. No. of Persons
Description No. of Days
No. Batches Per Batch
Maintenance & programming Training
1 2 4 5
at vendor site
2 Operations Staff Training 3 4 5
3 Basic Engineering trainning 2 4 5
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12.0 SPARES PHILOSOPHY AND CONSUMABLES :
12.1 Mandatory Spares : (Vendor to offer Separate offer with break-up for each items)
a I/O Cards - 10 % of each type of card, including relevant terminal modules/pre-fab system cables, etc. subject to
minimum of 1 no. each.
b Communication interface cards - 10% of each type of card, including relevant terminal modules/pre-fab system cables,
etc., subject to minimum of 1 no. each.
c Power Supply cards - 10% of each type of card, including relevant terminal modules/pre-fab system cables, etc., subject
to minimum of 1 no. each.
d 100% spares for all system Fuses and various glass fuses, 5% spares for each type relays including relevant terminal
modules/sockets, etc.
e 24 V DC Bulk Power Supply modules - Min.1 no. of each type
12.2 Commissioning Spares -
12.2.1 These are spares required for replacement during erection / commissioning and till the time of final handing over of the
system. DCS Supplier is fully responsible to ensure that adequate spares are arranged by him at site as and when
required, in shortest possible time, so that the site work is not affected. These spares shall be supplied free of cost. It is
left to the DCS Supplier's judgment to decide those spares to be maintained by him at site or those which can be
arranged by him from his works / sub-suppliers at short notice. The unused commissioning spares supplied by the DCS
Supplier shall be will be left with Client after successful commissioning.
12.3 Consumable Spares
12.3.1 Any paper, ribbon, printer heads and ink required for printers or any other consumable items shall be supplied along with
system required for minimum of three months duration after system acceptance.
13.0 AMC FOR NON-COMPREHENSIVE/COMPREHENSIVE ( optional offer) :
Post Warranty comprehensive AMC will be for a period of 3 years. This will be reckoned from the day the Warranty period is
completed. During this period, testing and complete maintenance of DCS system for proper functioning of the DCS system
shall be in the scope of the Vendor. Supply and installation / replacement of all defective spares in the DCS system will be in
the scope of the Vendor for comprehensive AMC contract. This will be considered along with the offer for evaluation. Vendor
should quote Lump-sum annual Non-comprehensive/comprehensive AMC charges. This charge should include the
associated cost such as all travel expenditures, boarding & lodging charges etc.
Vendor shall quote separately post warranty maintenance contract for a period 3 years from the date of completion of
warranty maintenance and shall meet the following requirements:
a Periodic and preventive maintenance:
Vendor shall depute qualified service engineers having at least three years of experience on maintenance of similar
system for regular system check ,general healthiness of the system (H/W, S/W, power supply, calibration testing
checks, solving of any reported problems etc) as a part of periodic maintenance including consumables required for
normal maintenance purpose. Vendor shall also include complete overhaul of the system, inspection of HW/SW, major
repairs, replacement and reporting. Vendor shall also give any other checks required for preventive maintenance and the
same shall be included. Generation and submission of diagnostic reports shall also be done by vendor
b Emergency service
The engineer must report at site within 12 hours of report of failure, with necessary spares(for comprehensive AMC). The
system must be brought back in operation within 24 hours after reporting at site.
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14.0 DOCUMENTATION :
14.1 ENGINEERING DRAWINGS
14.1.1 The vendor shall provide a complete set of drawings covering each part of the supply for the owner/consultant review and
approval. The vendor shall include owner’s project number on each of his drawings in order to ease owner/consultant’s
record keeping.
14.1.1.1 Documents to be provided by System Supplier along with the despatch : 3 sets
a Software documentation
b Input/output list with address
c DCS schemes showing modules/ hardware used in the system along with bill of materials.
d All interconnection details/ schedules.
e Instruction manuals.
f Operation and maintenance manual
g Loop wiring diagram/Wiring termination details
14.1.1.2 Documents to be provided with the Offer :
a I/O List.
b Detail Bill of material along with catalogues with make/model number including all bought out items.
c System diagram ( Architecture of the quoted system.)
d Dimension drawing for DCS panel & operator station.
e Heat load calculation & power consumption statement
f Detail schedule of job execution & proposed organisation chart for job execution
14.1.1.3 Documents to be submitted during Engineering for owner / consultants Approval :
a Dimensional drawings with internal hardware mounting details of System cabinets, marshalling cabinets, Power
distribution panel , Operator consoles/ station, engineering station including mounting details & weight.
b Calculation of total power requirements & heat dissipation.
c System Software documentation
d I/O Assignment details
e DCS scheme with BOM
f Loop wiring diagram / Wiring termination details
g Interconnection schedule
h Acceptance test procedure
i Plant QA / QC procedure
j Shop & laboratory facilities
k DCS configuration
l Logic diagram / Ladder drawings.
m Software loading calculations for various system nodes with spare margins available.
n Earthing detail drawings
o Control & cabinet room layout drawings with console bay arrangement details
p coloured printouts of all generated graphics
q Start up, Shutdown & Emergency procedure
14.1.1.4 Vendor to submit 2 sets of soft copies of all above final and as built drawing/documents
15.0 SHIPPING :
15.1 All the material used for packing, wrapping, sealers, moisture resistant barriers and corrosion preventers shall be of
recognized brands and shall conform to the best standards in the areas for the articles which are packaged.
15.2 Workmanship shall be in accordance with best commercial practice with the requirement of applicable specifications.
There shall be no defects, imperfections or omissions which would tend to impair the protection offered by the package
as a whole.
15.3 The package shall be suitable for storing in tropicalised climate, the ambient conditions being specified in the job
specifications.
15.4 Shipment shall be thoroughly checked for completeness before final packing and shipment.
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16.1 SUMMARY OF I / O COUNT ESTIMATION FOR 2,5 DCNB PROJECT:
I / O COUNT ESTIMATION FOR DCS SYSTEM

TOTAL BARRIERS
SI. INSTALLED INSTALLED RELAY
NO.
CATEGORIES OVERALL /ISOLATOR
BASE COUNT SPARE 30% COUNT
COUNT COUNT
1 AI - IS Close loops 57 18 75 75
2 AI - IS Open loops 176 53 229 229

3 RTD input Signal 109 33 142
4 AO - IS Close loops 57 17 74 74
7 5 DI -NIS (Field Switches ) 272 82 354
DI - With isolator (Field - Tunning Fork type
6 36 11 47 47
Level Switch)
DI - (Soft) from IMCC for Drives, Status , trip
7 242 73 315
& remote/local Indication
8 DI - Status/Trip Ind. From PKG panels 20 6 26
7 9 DO - (For ON/OFF Valve) With Relay 157 47 204 204
10 DO -(Soft) To IMCC for Start & Stop 172 52 224
11 DO - With Relay START/STOP To PKG 10 3 13

panels
12 AI- (SOFT) From IMCC 100 30 130
7 13 AO-(SOFT) TO IMCC 27 8 35
16.2 FINAL NO OF IO'S COUNT FOR AJANTA INFRASTRUCTURE. (AS PER AIL) INCLUDING I/O COUNT
FOR 2,5 DCNB AS PER ABOVE
I / O COUNT ESTIMATION FOR DCS SYSTEM

TOTAL BARRIERS
SI. INSTALLED INSTALLED RELAY
NO.
CATEGORIES OVERALL /ISOLATOR
BASE COUNT SPARE 30% COUNT
COUNT COUNT
1 ANALOG INPUT 1017 305 1322 1322
2 ANALOG OUTPUT 195 59 254 254
3 RESISTANCE TEMP DETECTOR 476 143 619
4 DIGITAL INPUT 1188 356 1544 72
5 DIGITAL OUTPUT 573 172 745 745
7
TOTAL COUNTS 3449 1035 4484
BOM FOR MAJOR HARDWARE
Sr
DISCRIPTION QUANTITY
no
1 DCS ENGINNERING STATION WITH SINGLE MONITOR 1 no
2 DCS OPERATING STATION WITH DUAL MONITOR
a FOR 2, 5 DCNB PROJECT-(AS PER SYSTEM ARCHETECTURE) 3 no's
b FOR CR STATION / TANK FARM (CONSIDERED AS PER I/O BY AIL) 2 no's
c FOR COLUMN (CONSIDERED AS PER I/O BY AIL) 1 no
d FOR 3,4 DCNB (CONSIDERED AS PER I/O BY AIL) 3 no's
3 A3 LASER PRINTER (BLACK& WHITE) 1 no
4 A4 LASER PRINTER (COLOUR) 1 no
5 DCS SYSTEM CABINET min 1 as required
6 MARSHALLING CABINET lot
7 PDB CABINET min 2 as required

Dcs Specifications DCNB

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Dcs Specifications DCNB

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INSTRUMENTATION SPECIFICATION

Zeppelin System India Pvt. Ltd., DCS SYSTEM

SPECIFICATION FOR DCS SYSTEM

DOCUMENT NO. : 3021-IN-SPC-001A

7 08-01-2020 REVISED AS PER CLIENT'S COMMENTS AYM DRS BAP

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

2.0 ENVIRONMENTAL CONDITIONS 3

3.0 CONTROL PHILOSOPHY 3

4.0 GENERAL SCOPE 4

5.0 DESIGN CONSIDERATIONS 6

6.0 DCS SYSTEM CONFIGURATION & FUNCTIONAL SPECIFICATIONS 10

7.0 BOUGHT OUT ITEMS INCLUDED IN DCS SUPPLIER'S SCOPE OF SUPPLY 22

8.0 TESTING AND ACCEPTANCE 23

9.0 INSTALLATION, TESTING AND COMMISSIONING 24

10.0 FINAL ACCEPTANCE AND WARRANTY 26

12.0 SPARES PHILOSOPHY AND CONSUMABLES 28

13.0 AMC FOR NON-COMPREHENSIVE/COMPREHENSIVE 28

16.0 SUMMARY OF I / O COUNT ESTIMATION 30

Name of client : Aarti Industries Ltd,Jhagadia,, BHARUCH

Project Name : 2.5 DCNB plant

Location : Jhagadia, Dist : Bharuch, Gujarat

2.0 ENVIRONMENTAL CONDITIONS :

Following environmental conditions shall be applicable :

2.2 Control Room

3.0 CONTROL PHILOSOPHY :

4.0 GENERAL SCOPE :

b Building of all operator interface, screen displays, database and reports.

c System Hardware & Software configuration.

f Proving of DCS system functionality as per requirements.

4.5.2 Supply and Inspection

4.5.3 Erection and Commissioning

5.0 DESIGN CONSIDERATIONS :

For hierarchical control system

5.2 Hardware Requirements

5.3 Software Requirements

5.3.18 License Report Package software shall be considered

5.4 Redundancy Requirements :

5.4.1 Hardware /software Redundancy requirements at various levels are as follows:

5.5 System sizing / loading criteria

a 60% : Processor including memory

5.6 Power supply distribution

5.6.1 Power Supply Levels

Sr. No. Type of Load Supply Type

6.0 DCS SYSTEM CONFIGURATION & FUNCTIONAL SPECIFICATIONS :

6.1 System components

6.2 Functional requirements

6.3 Processor system

a General : Monitoring and alarms

6.4 I/O System

a Analog I/O Modules : 8/16 channels

6.5 Operator interface system (Qty-3 nos in main control room)

6.5.10 Each OS shall have the following specifications:

6.5.11.1 Overview display

6.5.11.2 Group Display

d Processor mode i.e. auto, manual, cascade.

e Process alarm on process variable, deviation.

g Control valve failure position.