Specification of DCS and ESD based control systems for projects of manufacturing industries shall include Design, Engineering, Manufacturing, Software Development, Supply of DCS & ESD systems with SCADA, Erection, Supervision, Commissioning, etc.
This article covers the scope of work for the DCS and ESD systems and their general technical evaluation, specifications, and requirements.
Control System vendor shall provide system solution as a standard DCS/ESD. A hybrid type solution is not acceptable. Separate hardware and software shall be considered for DCS and ESD.
DCS architecture should be Node Based and not server based. ESD system shall be independent and shall be minimum SIL-3 rated.
DCS and ESD systems shall be redundant.
The systems shall have redundancy at the following levels.
Transfer of control shall be achieved in an order of 100ms. The failed module when replaced shall update the program from the running processor. It shall be possible to make the hot-standby processor learn from the active processor and update itself to function as a hot-standby.
The standby processor shall continuously equalize with the primary processor. There shall be Bump less Transfer of control between Active Processor and Standby Processor.
The processor should be 64 Mbytes memory. The DCS and ESD system should be suitable to operate continuously in a given atmospheric condition. Hence the system hardware shall be considered with anti-corrosive G3 Coating as per Standard ANSI/ISA S71.04-1985.
DCS and ESD shall have extensive self-diagnostic capabilities and the capacity to identify any faulty channels in input/output cards, faulty system cards, power supplies, etc. ESD System I/O cards shall be hot swappable.
Since the ESD system is intended to be used for Plant safety applications, the following failure effect of the ESD system shall be evaluated and addressed in the design.
Operator stations shall be industrial grade and designed such that no plant data/system configuration will be lost in the event of any component failure to the maximum extent possible.
The vendor/client should select DCS and ESD hardware modules after understanding the total process requirement.
In I/O modules, the following configuration shall be generally followed:
Standalone control panels/cabinets (Rittal/Eldon/Hoffman make), and bottom cable entry should be considered.
Panels shall have doors on the Front and Rear Side with Double Front & Double Rear Doors.
The control panel shall have ingress protection IP 52 as a minimum. Preferred Panel size [HxWxD]mm: [2100mm(2000mm+100mmplinth)] X [1200mm(600mm+600mm) Doors] X [800mm].
Paint shade for interior and exterior RAL7035 and Paint shade for base frame/Channel Base shall be RAL7022.
In the control panel/cabinets, there shall be 30% of spare space for future local expansion if any.
The marshalling cabinets shall be separate for Analog I/O’s and separate for DI’s & DO’s. Interposing relays shall be provided for all the digital outputs.
The system cabinet consists of all types of electronic modules including CPU, I/O modules, etc. The node Interface units (NIU’s) should be on the front side of the system cabinet. Power and signal wiring shall be separated.
The system shall include the required software for DCS/ESD and the programming terminal. Programming software shall be preloaded on the Engineering station and a CD shall be delivered along with the system.
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HONEY WELL DCS AND ESD TRAINING