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CHAPTER-1
INTRODUCTION
Yokogawa Electric Corporation is a Japanese electrical engineering and software
company, with businesses based on its measurement, control, and information
technologies. It has a global workforce of over 19,000 employees, 88 subsidiary and
3 affiliated companies operating in 56 countries. The company is listed on the Tokyo
Stock Exchange and is a constituent of the Nikkei 225 stock index.
Yokogawa pioneered the development of distributed control systems and introduced its
Centum series DCS in 1975. Some of Yokogawa's most recognizable products
are production control systems, test and measurement instruments, pressure transmitters,
flow meters, oxygen analyzers, field bus instruments, Manufacturing Execution Systems
and Advanced Process Control.
1.HISTORY
Yokogawa traces its roots back to 1915, when Dr. Tamisuke Yokogawa, a renowned
architect, established an electric meter research institute in Shibuya, Tokyo. After
pioneering the development and production of electric meters in Japan, this enterprise
was incorporated in 1920 as Yokogawa Electric Works Ltd.
In 1933 Yokogawa began the research and manufacture of aircraft instruments and flow,
temperature, and pressure controllers. In the years following the war, Yokogawa went
public, developed its first electronic recorders, signed a technical assistance agreement
for industrial instruments with the U.S. firm Foxboro, and opened its first overseas sales
office (New York).
In the 1960s the company made a full-scale entry into the industrial analyzer market and
launched the development, manufacturing, and sales of vortex flow meters, and in the
decade following established its first manufacturing plant outside Japan (Singapore),
opened a sales office in Europe, and became one of the first companies to bring a
distributed process control system to market.

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In 1983 Yokogawa merged with Hokushin Electric Works and, towards the end of the
decade, entered the high-frequency measuring instrument business. In the 1990s,
Yokogawa established an office in Bahrain to oversee its business in the Middle East and
entered the confocal scanner and biotechnology businesses.
In 2002 the firm continued its growth with the acquisition of Ando Electric, and in 2005
set the stage for a new level of globalization in its industrial automation business with the
establishment of Yokogawa Electric International in Singapore. In 2008 the company
entered the drug discovery support market with a new bio test system.
2. BUSINESSES
2.1 Chemical
Being a producer in the chemical industry has become more and more challenging over
the years. Customer needs for products, pricing, and delivery are more demanding and
material requirements have become complex and ever-changing. Additionally,
compliance in environment health, safety and security have always been primary
requirements to do business. Throughout the years, Yokogawa has partnered with many
chemical companies to provide technology solutions that help overcome these challenges.
2.1.1 Bulk & Petrochemical
Whether you produce petrochemicals, in organics or intermediates, chemical companies
are under cost and margin pressures to deliver products in a timely and efficient manner
while maintaining safe and compliant operations. Additionally, chemical companies need
to adjust to fluctuating feedstock and energy prices and to provide the most profitable
product mix to the market.Yokogawa has been serving the automation needs of the bulk
chemical market globally and is the recognized leader in this market.
2.1.2 Ammonia
Ammonia producers are faced with rapid growth combined with many older control
systems. Growth is driven by global demand for fertilizer and supported by cheap and
plentiful shale gas.
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Yokogawa is the leading automation supplier to the ammonia and methanol industry. Our
reputation for reliability, along with global install base in ammonia with Main
Automation Contractor capabilities translate to lowest total life-cycle cost to customers.
Yokogawa has unique analytical offerings such as TDLS and a KBR partnership with
process licenses in 54% of North American install base and will use Yokogawa
automation technology as part of the process license.
2.1.3 Specialty & Fine Chemical
Specialty Chemical plants typically rely on batch production processes, which adds a
level of complex procedural requirements to a control system. The emphasis with a batch
process is having a control system that allows great flexibility in making adjustments to
formulas, procedures, and the like. Control systems need to be managed in available
quality history of product, and to be able to execute non-routine operations. With its
extensive product portfolio, experienced systems engineers, and global sales and service
network, Yokogawa has a world class solution for Specialty Chemical Batch applications.
2.1.4 Lube Oil Blending
In Lubricant and Grease manufacturing there are ever-changing complex formations
whether material is processed in an in-line blending system or in a batch process. This
emphasis, requires a control system that allows great flexibility in making adjustments to
formulas, procedures, and need to be managed in available quality history of product, and
to be able to execute non-routine operations.
With its extensive product portfolio, experienced systems engineers, and global sales and
service network, Yokogawa has world class solutions for lubricant manufacturing
applications in many areas such as:

Recipe Validation

Automatic valve sequencing

Blend Property control

Advanced Monitoring of Emergency Stop Conditions

Property trimming control

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Flexible Batch sequencing

Terminal Automation

Tank Farm Inventory measurement and tracking

ERP Workflow and production interfacing

Advanced LIMS interfacing

Path and product transfer line compatibility management

2.2 Oil & Gas Upstream

Upstream automation is focused on the drilling, completion, extraction, and separation
components of the oil and gas ecosystem, leading up to midstream transport and
downstream processing and conversion. The upstream industry includes offshore and
onshore activities including wellhead automation, fractionation, completion, and
separation to recover and prepare underground or underwater crude oil and natural gas.
As petroleum is brought to the surface, it must be separated prior to transport. Primary
and secondary separation stages commonly distribute gas flow, water flow, and oil flow
in three phase separation. Gas movement requires pipeline and can include a fractionation
process in the upstream stage prior to movement. Liquids can be placed into a tanks or
pipelines and sent for processing, requiring accurate level measurements.
2.2.1Onshore
The onshore upstream industry faces ever higher demands and greater challenges with
increasingly difficult and hostile environments in which it must operate. As the
unconventional natural gas resources opportunities, particularly shale gas, are growing in
North America, Yokogawa's total solution plays an important role helping customers
meet the challenges of reducing both CAPEX and OPEX, while enhanced built-in
technologies increase production.
2.2.2Offshore
Offshore exploration and production requires maximum uptime under harsh conditions.
Manned and unmanned facilities need reliable integrated control and safety systems
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(ICSS) with advanced remote monitoring capabilities. Yokogawa has state-of-the-art
technology and extensive experience in executing offshore projects of all sizes and
automation levels of complexity.
2.3 Oil & Gas Midstream
Yokogawa's innovative technology platforms and industry leading execution is well
regarded in the global marketplace as a solutions partner pioneering the integration of
technologies for all aspects of the oil & gas ecosystem from reservoir to enterprise.
Proven solutions that include predicative business modeling, plant optimization and
highly reliable automation platforms are assisting midstream operators to run their
businesses at the optimal efficiencies.
2.3.1 Pipeline
Pipelines and Local Distribution Companies (LDCs) provide an essential service by
transporting and delivering natural gas, crude oil and refined petroleum products safely
and efficiently. Pipeline SCADA and automation systems are required for monitoring and
control of pump and compressor stations, meter stations, storage fields, terminals and
other assets.
2.3.2 Gas Processing
The midstream natural gas gathering and processing industry is experiencing incredible
growth driven by the shale play revolution. The industry is challenged with managing
growth and profitability under constantly fluctuating economic and operational
conditions. A comprehensive solution that includes predictive business modeling, plant
optimization, and industrial automation is required. With the recently announced strategic
alliance between Yokogawa and eSimulation, a comprehensive platform is now available
to help manage and optimize economic and operational interactions across the enterprise.
2.4 LNG Supply Chain
For over 30 years, Yokogawa has delivered field proven engineering, automation,
measurement and control solutions to the LNG industry to help reduce project risk and
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implementation cost. With availability of 99.99999%+ across more than 20,000 installed
systems, you can depend on Yokogawa as your global LNG Automation Partner.
2.5 Power
In the mid 1970s, Yokogawa entered the power business with the release of the EBS
Electric Control System. Since then, Yokogawa has steadfastly continued with the
development of our technologies and capabilities for providing the best services and
solutions to our customers worldwide. Yokogawa has operated the global power solutions
network to play a more active role in the dynamic global power market. This has allowed
closer teamwork within Yokogawa, bringing together our global resources and industry
know-how. Yokogawa's power industry experts work together to bring each customer the
solution that best suits their sophisticated requirements.
2.5.1 Renewable Energy
The use of renewable energy protects the environment and takes both society and
industry closer to the goal of achieving sustainability. However, compared to
conventional energy sources, there are certain challenges that stand in the way of its rapid
adoption, such as higher production costs and greater instability in the supply of power to
the grid. As a leading company in the control and instrumentation business, Yokogawa
has always striven to help its customers in various industries achieve stable operations
and improve productivity in their plants. Based on our Vigilant Plant concept for attaining
operational excellence, we are providing solutions that pave the way to the use of
renewable energy sources.
2.6 Refining
In the ever changing marketplace, refineries are seen not only as crude processing units
but also as profit centers. At the same time, there is a keen awareness of the need for
safety at such facilities. A total production solution that encompasses planning,
scheduling, management, and control is required to achieve long-term goals for
profitability, efficiency, and environmental protection.

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2.7 Water & Wastewater
Yokogawa delivers cost benefit solutions through the water and wastewater plant controls
and instrumentation. This improves the performance of plants and ensures that they can
operate competitively in today's water markets, and also reduces their operation costs.
Yokogawa assists plant owners to identify areas of plant operations that benefit from
modern controls running on the latest digital control system platform, with modern field
instrumentation. Yokogawa supports a wide range of control applications in both
municipal and industry market.
2.8 Pharmaceutical
The pharmaceutical industry currently faces a major challenge in taking full advantage of
the opportunities presented in large emerging markets. And more than ever,
pharmaceutical companies need to introduce lean manufacturing techniques that will
enhance profitability. As one of the world's leading industrial automation suppliers,
Yokogawa is committed to delivering the best possible solutions for your best
manufacturing practices.
2.9 Metal Mining, Cement & Glass
Mining operations produces valuable minerals or geolocial materials from the Earth.
Economical recovery often requires high throughput and high availability of the process
with low operation costs, and stringent safety and environmental regulations. Similarly,
float glass production and automated production of cement in process kilns can benefit
from capital investments in energy efficiency, advanced process control, and
environmental compliance.
Yokogawa provides integrated production control systems (DCS), transmitters, magnetic
flowmeters, pH analyzers and a local area plant network. The fully redundant DCS
enables high process availability at an economical cost. Integration of the motor
protection relay diagnostics into the control system significantly reduces maintenance
times.

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2.10 Food & Beverage, Pulp & Paper, Iron & Steel
Industry leaders striving for operational excellence will benefit from a new vigilant
approach to plant automation. Yokogawa helps you see, know and act with greater
confidence and ease with field-proven tools and services.
3. PRODUCTS & PLATFORMS
3.1 Distributed Control System (DCS)
Yokogawa offers multiple automation and control strategies, architectures, and solutions
for every application size and complexity. Our distributed control system (DCS) is
designed for large, complex industrial processes, and geographically distributed
applications. The DCS can employ advanced process/supervisory control applications,
operator-centric, enterprise-integrated information, configuring disparate systems into a
holistic process overview and coordinated control strategy. A DCS utilizes a more
distributed node topology and is often implemented with Yokogawa as a single source of
responsibility. CENTUM VP is the latest generation of the CENTUM DCS series.
CENTUM VP features unrivaled 99.99999% availability along with an intuitive human
machine interface and a versatile field control station suitable for both large and small
scale data processing tasks.
3.2 Safety Instrumented Systems (SIS)
Industrial processes and plants increasingly experience concern about potential incidents
that can affect people, assets and the environment in and outside the plant. A safety
instrumented system (SIS) can dramatically reduce the risk of accidents in your plant.
The ANSI/ISA 84 functional safety standards is widely used to implement safety
instrumented systems and are 'good engineering practices in relation to Process Safety
Management' (OSHA PSM 29 CFR Part 1910).In the continuously evolving process
industry, the need for expansion and upgrades of aging safety platforms and
infrastructures is undeniable. Yokogawa understands your need to implement a safety
system that is compliant with the new safety regulations, such as the ANSI/ISA 84 and
NFPA standards.

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Our expertise covers all major applications such as ESD (Emergency Shut Down), F&G
or FGS (Fire and Gas Systems), BMS (Burner or Boiler Management Systems) as well as
HIPPS or HIPS (High Integrity (Pipeline) Protection Systems).
Yokogawa has over 50 years of experience in the development and implementation of
safety systems and is the world's most trusted automation solutions partner for efficient
project execution and safety system solutions.
3.3 SCADA Systems
Supervisory control and data acquisition (SCADA) systems are typically used for
monitoring and control of small or large-scale processes which can span multiple sites
across large distances. Common applications include oil & gas production fields,
pipelines, water and wastewater. Yokogawa's SCADA portfolio includes hardware and
software SCADA technologies.
3.4 Process Controllers (PID/PLC/RTU)
Process controllers maintain an environment based on a set of specific rules by reading
levels, temperatures, pressures and speeds, adjusting them to meet application
requirements.
3.5 Field Instruments
Yokogawa field instrument products includes a complete line of flowmeters, pressure
transmitters, differential pressure transmitters, temperature transmitters, level
transmitters, Fieldbus instruments and safety measurement instrumentation.
3.6 Process Analyzers
Process analyzers are on-line tools for industrial process analytics. They are used to
determine the chemical composition or physical properties of substances involved in
industrial processes. They enable process optimization, asset protection, and compliance
with environmental regulations. With one of the most comprehensive families of sensors
and on-line analyzers for pH, conductivity, dissolved oxygen, combustion oxygen,
humidity, liquid and gas density and process gas chromatography.
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Yokogawa is recognized as a world leader in the field of analytical equipment. Accurate,
repeatable measurement is the key to obtaining optimal results in your process, and
Yokogawa's diagnostic-based analytical instrumentation offers the flexibility to meet a
range of individual requirements. Whether for liquid or gas applications, our analyzers
can resolve even the most demanding situations. Yokogawa's leadership in process
analytics helps to protect the environment by reducing energy consumption and
CO2 emissions.
3.7 Data Acquisition
Data acquisition (DAQ) is the measurement, recording, analyzing, and presentation of
real world phenomena. It includes electrical measurements such as voltage, current,
power as well as measurements through sensors and transducers including temperature,
pressure, flow, level, strain, acceleration, pH, humidity, and more.
Selecting the ideal data acquisition components or solution depends on your application.
Typical factors include sample rates, channel scalability, signal conditioning, sensor
types, analysis capability, mobility, and environmental conditions.
Yokogawa data acquisition solutions are recognized for industry leading measurement
accuracy, noise tolerance, and build quality. These include most industrial networking
protocols, all-in-one architectures, and typically require no programming.
3.8 Industrial Networking
Getting measurement and control signals to and from your instruments is central to your
automation strategy. Yokogawa supports a wide variety of Fieldbus technologies,
including conventional 4-20mA, wired digital networks, and wireless ISA100.11a. These
technologies are employed at the device, host, and solution level, depending on your
needs.

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3.9 Test & Measurement Instruments
Yokogawa has been developing measurement solutions for nearly 100 years, consistently
finding new ways to give R&D teams the tools they need to gain the best insights from
their measurement strategies. As well as offering a wide ranging product lineup and an
extensive range of calibration and other services, the company has pioneered accurate
power measurement throughout its history, and is the market leader in digital power
analyzers.
Yokogawa instruments are renowned for maintaining high levels of precision and for
continuing to deliver value for far longer than the typical shelf-life of such equipment.
Yokogawa believes that precise and effective measurement lies at the heart of successful
innovation and has focused its own R&D on providing the tools that researchers and
engineers need to address challenges great and small.
Yokogawa takes pride in its reputation for quality, both in the products it delivers often
adding new features in response to specific client requests and the level of service and
advice provided to clients, helping to devise measurement strategies for even the most
challenging environments.
4. SOLUTIONS
4.1 Production Management
Production Management consists of systems and methods that are used to control and
optimize the manufacturing of products and materials in industrial plants and facilities.
Software solutions used in the role range from advanced multi-variable process control to
Manufacturing Operations Management (MOM) solutions or Manufacturing Execution
Systems (MES). Yokogawa provides many solutions in this area including Process
Information Management Systems (PIMS) and Operations Management through to realtime model based process control and optimization.
4.2 Alarm Management
A widespread issue in manufacturing plants is alarm overload. As formerly independent
systems are integrated for more effective operation by fewer operators, each operator has
to monitor an increasingly wider area and consequently deal with more alarms. Without
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rigorous alarm rationalization efforts, alarm flooding becomes a serious problem and
increases the risk of safety and environmental incidents.There are a number of documents
such as EEMUA #191 and ISA 18.2 that help customers reduce alarms, but practical tools
that can be implemented are still in short supply. Yokogawa proposes a smart approach to
alarm management that helps customers achieve safe and agile plant operations based on
the concept of combining practical bottom-up solutions with fundamental top-down
improvements.
Yokogawa urges customers facing alarm flooding situations in their plants to introduce
CAMS for HIS. It also benefits those who are looking for alarm management capabilities
that go beyond the current generation of DCS alarm systems. Customers planning to
consolidate their control rooms and design their alarm system to be in compliance with
the ISA 18.2 standard will benefit from this product's practical and immediate solutions.
4.3 Process Safety Management
Process safety management (PSM) is a regulation from the US. Occupational Safety and
Health and Administration (OSHA) applicable to all processes that engage in the
production, movement, storage or use of any Highly Hazardous Chemicals as defined in
OSHA (29 CFE 1910.119). The intent of the regulation is to reduce the severity and
frequency of incidents resulting from the release of chemicals and other energy sources.
OSHA's standard emphasizes s a comprehensive management program that integrates
technologies, procedures, and management practices. Yokogawa has dedicated services
and solutions to help our customers meet these regulations and protect their employees
and assets.
4.4 Operator Effectiveness
Recognizing that an operational error in process plants is one of the major reasons for
significant financial losses, Yokogawa has introduced Advanced Decision Support (ADS)
to assist operators in making the right decisions at times of increased stress such as
during the initial stages of operation or during abnormal conditions. The ADS concept is

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designed to use best practices to assist operators in semi-structured or unstructured
decision-making processes to support their judgment.
ADS consists of three key functions, alarm management, HMI management, and
procedure management implemented in the Process Control System. ADS is a consulting
methodology based on Yokogawa consultants specializing in fields such as knowledge
engineering and ergonomic design. This combination can help customers effectively
integrate, engineer and operate the above mentioned functions based upon ISA18.2,
ISA101 and ISA106 standardized approaches.
4.5 Operator Training Simulators
Make every operator your best operator. Operator Training Simulators simulate your
process. Operators can practice startup and shutdown procedures in a safe environment,
before the actual event. Induce problems so if they are encountered during the startup
and shutdown (or normal running) the operator already knows the solution. Simulation
fidelity can be low, medium or high depending on your needs.
4.6 Vertical Market Solutions
Yokogawa offers a myriad of focused solutions that address customer's operational issues
and improve accounting accuracy, asset and energy management, and optimize
production and inventory management.
5.SERVICES
5.1 Engineering Services
Yokogawa delivers a total automation solution, covering the entire lifecycle of projects,
as your automation partner. This proven method brings experience, engineering,
technology, safety, and lifecycle support. It reduces risk and lowers overall costs.
5.2 Instrumentation Services
Yokogawa offers a variety of instrumentation services including:

Calibration and Certification

Installation / Loop Check / Startup

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Preventative and Corrective Maintenance Services

Emergency Repair

Programming and Troubleshooting

Factory Repair / Flow Testing.

5.3 Calibration and Certification

On-site calibrations are performed in accordance with agreed to schedules to ensure
specific industry regulatory standards are fully met. All equipment used is certified and
fully traceable according to the National Institute of Standards and Technology (NIST).
All work is fully documented and calibration stickers are included for individual devices.
5.4 Installation / Loop Check / Startup
Yokogawa will provide cost effective installation, loop check and startup solutions that
can be ordered with your initial product purchase. Installation will be performed to
manufacturer's specifications. Loop check will be performed to verify that the expected
output to the final control element is produced. Startup will include functional tests and
on-site configuration of instruments and analytical products. This ensures dependable and
timely startup and continued operation.
5.5 Preventative and Corrective Maintenance Services
When telephone support cannot solve an immediate problem, emergency on- site
assistance may be necessary. An experienced field Service Specialist will be dispatched
to your plant. Yokogawa can provide programming, optimization, repair or replacement
for all manufacturers' equipment.
5.6 Emergency Repair
Testing Yokogawa can perform repair and calibration on the full line of Yokogawa
instrumentation. Preventative maintenance services help maximize the performance of
instrumentation and control equipment. It ensures proper operation by utilizing advanced
predictive maintenance diagnostics, cleaning and periodic maintenance including
consumable replacements. Corrective maintenance service contracts are available for
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customers requiring specific response times for crucial processes. Yokogawa utilizes
advanced diagnostic and repair practices to resolve issues quickly.

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CHAPTER 2
ABOUT THE DEPARTMENT
The department is called as Engineering Centre. The projects taken up will follow the
below steps:
1.Major activities in project engineering:
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15

IKOM(internal kick-off meeting)

Sale order updation
CKOM (customer kick-off meeting)
Basic engineering
Detailed engineering
SDM(system definition meeting)
Design review
Transfer of documents to panel department for manufacturing
Staging
Pre FAT
FAT
Dispatch advice
Dispatch of system to site
Final documentation
Job transfer to FES

1.1 IKOM(Internal Kick-Off Meeting)

1.1.1 Sales and Projects
The following points to be discussed and documents to be collected from sales.

Project Overview, background, customer and Project Significant

Clarify the Project Requirements

Scope of work

Project Schedule and plan

Discuss project deliverable

Project Risk Identification and Analysis.

Distribute contact list

Issue list

Minutes of Meeting with sales

1.1.2 Documents from Sales:

Customer Enquiry

Final Sales Offer

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Deviation List

MOM & other Correspondences

LOI/PO/PR

Special Requirement

Delivery Date

Scope of work

Agreed T&C

Man-hour estimate by Sales

Project costing by sales

Project Schedule by Sales

1.1.3

IKOM output documents:

Output documents from projects department:

New Job Intimation to all concerned

Project charter

Man Hour Estimation

Project Costing by Projects

Risk Register

1.2 Sale Order Up-Dation: Sale Order Updation (SAP) for Factory Material , Product
and Bought-Outs based on IKOM.
1.3 CKOM(Customer Kick-Off Meeting)
Objective of the Customer Kick off Meeting is to collect the Engineering Input
documents from Customer(i.e., IO list, functional Specification & Operation Philosophy
etc.). If required site survey also to be done.The following document to get approval from
customer during CKOM meeting.

Document Index & Schedule

Customer Document Index & Schedule

Communication Protocol

Project Team Orgainzation

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1.4 Basic Engineering Documents
SCD(System Configuration Drawing)
BOM(Bill of Material)
Channel Base Drawing
Power Consumption & Heat Dissipation
Power Distribution Drawing
Grounding Scheme
Control Room Layout
Cabinet General Specification
1.5 Detailed Engineering Documents
Typical GA & IA Drawing

Typical Console Drawing

Typical Loops

Typical Channel base Drawing

Grounding Scheme

Functional Design Specification(FDS)

Nest Loading & Front Loading

Interconnection cable Schedule

FAT Procedure

1.6 SDM(System Definition Meeting)

System Definition meeting is to finalize all the typical engineering documents.

Project philosophy to be finalized.

1.7 Design Review Meeting

Design review meeting is to get all engineering document approval.

1.8 Transfer of documents to MFG/ panel department for manufaturing

The following document to be transfer to Manufacturing department to start

manufacturing activities.

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GA & IA of System/PDB Cabinet

GA & IA of Marshaling Cabinet

GA & IA of consoles

Manufacturing Specification

Printer table drawing

1.9 Staging

All the material collected from stores and stage it in factory for testing.

1.10 Pre-FAT: PRE-FAT will be conducted as per FAT Procedure

1.11 FAT FAT will be conducted as per Approved FAT Procedure document.
1.12 DISPATCH ADVISE
Dispatch Advise issued to Logistic department for dispatching the materials.

After dispatch the material Logistic department will issue Packing list to Project
department.

1.13 DISPATCH OF SYSTEM TO SITE: Material will be dispatched to concern from

Logistic department.
1.14 FINAL DOCUMENTATION: Final Documentation shall be done based FAT
changes and same shall be transmitted to customer.
1.15 JOB TRANSFER TO FES: Documents will be transfer to FES as per Job transfer
to FES check list(QMSE format).
2. Tools & Techniques Used
2.1 Distributed Control Systems - CENTUM VP
CENTUM VP is Yokogawa's latest integrated production control system, also known as a
distributed control system (DCS). Nearly 40 years of knowledge and experience with
DCSs has gone into its development.

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CENTUM VP has a more intuitive human machine interface and power field control
stations capable of processing data faster and more reliably. Thanks to features such as a
pair & spare CPU configuration, CENTUM VP achieves 99.99999% (seven-9s)
availability.
CENTUM VP is the core platform of Yokogawa's Vigilant Plant solutions, that are
designed to achieve the ideal plant. CENTUM VP also is a highly reliable platform that
provides system operators integrated access to intelligent instrumentation diagnostics and
subsystem data.
CENTUM VP complies with the rules and requirements of the VGB R170C guidelines
developed by VGB PowerTech which represents the interests of power plant operators as
well as power industry related manufacturers and institutions.
CENTUM VP consists of four components which are operation and monitoring functions,
engineering functions, control functions, and a network communication system. It can be
flexibly configured to suit the requirements of plants both large and small in a wide
variety of industries.
In addition, integration with ProSafe-RS safety instrumented systems, STARDOM
network-based control systems, and different generations of CENTUM systems extends
its scope of operations.CENTUM VP also manages plant assets with Plant Resource
Manager.
Yokogawa has sold over 25,000 CENTUM projects in all kinds of industrial plants
worldwide such as oil and gas, petrochemicals, chemicals, power, pulp and paper,
pharmaceuticals, food, iron and steel, waste, and water and sewage treatment. The
majority of the customers are from oil and gas, and petrochemical industries. It means
that once the CENTUM system is delivered and start its operation, it has to be in
operation non-stop.

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In the past 40 years of experience, Yokogawa is reputed with the high reliability of the
CENTUM system winning customer satisfactions. Yokogawa is engaged in the global
purchase agreements with world major customers as their sole instrumentation supplier.
Yokogawa needs only one project to convince customers of our capability and win trust.
Once Yokogawa system is delivered, customers stay with Yokogawa.
CENTUM VP is designed based on the concept to keep the plant operation availability
high. Customers expect Yokogawa products to perform its functions without failure so
that the plant operations shall not stop. Yokogawa developed our own FCSs so that we
can meet up with the customers expectations. Quite a number of FCSs are still in
operation even after 20 or more years passed since those are originally installed. It is
owing to the high quality of the products themselves that has been supported by the total
serviceability such as skilled manufacturing, quality control, after sales service and
appropriate training.
2.2 Batch Automation
Batch automation processes have sequential processing steps each with unique failure
recovery routines. Every project presents unique requirements to achieve safe, flexible,
and expandable solution. CENTUM VP Batch is the ISA-88 (IEC-61512) batch control
package, which provides recipe management and process management functions
interfaced to the CENTUM VP standard unit supervision function.

2.3 Progressive Compatibility

The upgrade path for every CENTUM system is carefully considered as new versions are
developed. Yokogawa's exclusive ownership of CENTUM development throughout the
history of its DCS platform translates into customer benefit during system
upgrades. Since 1975, CENTUM users enjoy the industry's lowest total cost of ownership
over the plant lifecycle with a progressively compatible upgrade path and rock-solid
reliability.
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2.4 Agile Project Execution
Agile Project Execution provides new engineering possibilities and changes the way
projects can be planned and executed, reducing risk and adding flexibility to the
schedule.
2.5 Process Safety System ProSafe-RS - World's First Truly Integrated Safety
Controller
Achieving absolute integrity between distributed control systems (DCS) and safety
instrumented systems (SIS) for plant automation has traditionally raised complex design
and integration issues. Conventionally, two separate monitoring and operating
environments were required for a DCS and SIS. Different communications and
distinctive hardware architectures had to be set up. Plant managers striving to optimize
process operations have taken it as a given that project time and expenses would escalate.
Now Yokogawa puts an end to DCS-SIS incompatibility with the new ProSafe-RS, the
world's first truly integrated "safety PLC" for the process industries.
2.6 Process Safety System ProSafe-SLS
Yokogawa is the world's most experienced safety and control firm. Our commitment to
providing reliable, state of the art safety instrumented systems is rooted in a wealth of
installations since 1962.The solid-state, hard-wired ProSafe-SLS covers all requirements
in process industries. The product line covers specific requirements for individual safety
instrumented systems and offers all safety integrity levels (SIL 3-4) for the oil & gas,
petrochemical, chemical industries. ProSafe-SLS safety instrumented system is also fully
integrated with Yokogawa's CENTUM VP/CS 3000 process control system.
2.7 SCADA Systems: SCADA Hardware - STARDOM FCN
2.7.1 Never Interrupts Your Process
High reliability is essential for the systems that control your critical processes. The dual
redundant capability of the field control node (FCN) autonomous controller ensures that
these processes continue without interruption even when a damaged module is replaced.
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CPU unit, power supply unit, fieldbus module, and control network can all be
dual redundant.

Automatic switchover to stand-by CPU.

Automatic data transfer from control side to replaced stand-by CPU.

Hot-swappable modules including CPU.

Fault-tolerant design.

2.7.2 Automatic switchover without interrupting your process

If the control-side CPU fails, the stand-by CPU automatically detects this and takes over
control. To maintain consistency, all process data is synchronized on the stand-by and
control-side CPUs. When a hot-swappable CPU module is replaced, the module
automatically functions as the stand-by CPU by synchronizing both application and
database without interrupting the process. No PC tools are required to perform this
synchronization.
2.7.3 Easy Engineering for Redundant Applications
No special engineering work or dedicated CPU modules are required for redundant
applications. The stand-by and control CPUs also use the same spare parts, allowing users
to keep fewer parts in stock.
2.7.4 Minimize TCO by Minimizing Replacements
Power failure during disc access is a major cause of file corruption in the CPU module.
Without having to replace the entire CPU module, it is possible to recover a damaged file
system by replacing just the FCN system card.

2.8 HMI & SCADA Software FAST/TOOLS

HMI and SCADA software allows operating personnel to graphically view, control, and
analyze industrial processes. FAST/TOOLs is scalable from small HMI to enterprise
systems with over a million tags. FAST/TOOLS is a powerful, state-of-the-art, flexible,
distributed operations information and supervisory control system. It is a leading package
utilizing the latest best in class IT technology for these applications and is available on a
wide range of industry-standard computer systems.

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FAST/TOOLS provide solutions for a wide range of control and supervisory applications
where, for example one or more of the following requirements apply:
Multiple Process Site environments
Integration of third party systems
Wide Area (Media independent) communication
Robustness for intermitted communication
Security against unauthorized access
Disaster recovery and high availability architecture
Alarm & Event management, Trending & Reporting
These characteristics are often seen in for instance:
Oil & Gas production and transport, infrastructure, utilities and energy management
Critical manufacturing applications It also allows the flexibility of combining different
types of systems to provide hybrid solutions, both on new and existing sites (green and
brown field development).Many global industrial companies and utilities rely on
Yokogawas SCADA System FAST/TOOLS. The system is used to manage production
processes while guarding availability and efficiency in a way that maximizes return on
investment and minimizes cost of ownership. FAST/TOOLS success, in many of these
critical applications, is based on its highly reliable open architecture design, support of
quadruple redundancy and its on-line configuration possibilities. These properties
contribute to high efficiency and high quality production processes.
FAST/TOOLS has been developed with a number of key issues in mind, one of which is
the provision of a system that can start small and which can easily grow with short and
long term application needs. This guarantees your investment against premature
obsolescence. Furthermore as a hardware and operating system independent supplier
Yokogawa is committed to the support of standard operating systems, standard network
protocols, standard user interfaces and standard software development tools.

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FAST/TOOLS has been developed with over 35 years of experience by combining our
expertise in Supervisory Control And Data Acquisition (SCADA) with requirements from
users and industry leaders. The FAST/TOOLS package is a powerful, modern, flexible,
distributed operations information and control software package. It implements a Webbased supervisory control human machine interface, OPC server/client functions, data
acquisition from a variety of controllers and devices, alarm management and historical
data management. Furthermore it is a leading system package for operations control and
information integration with business systems and is available on a wide range of
industry standard operating platforms. Many industries and utility companies with a need
for data integration and data integrity use FAST/TOOLS from Yokogawa in their
applications.
FAST/TOOLS is also successful in critical applications due to its very reliable design,
support of redundant and nonstop systems and its on-line configuration capabilities.
These properties contribute to high efficiency and high quality production processes.
FAST/TOOLS has been developed with a number of key issues in mind, one of which is
to provide a system that can start small and which can easily grow with client needs, both
in the short and long term. This philosophy protects against premature obsolescence. The
consequence of being a hardware independent supplier means support of standard
operating systems, standard network protocols, standard user interfaces and standard
software development tools.
FAST/TOOLS provides solution possibilities in a wide range of control execution
applications with the following characteristics:
Multiple Process Site environments
PLC/RTU based control systems
Wide area communication
Intensive (mission critical) control performed by subsystems
Relatively high content sequential (logic) control.

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These characteristics are often seen in for example Oil & Gas production and transport,
infrastructure, utilities monitoring and control and high performance manufacturing
applications. It also allows the flexibility of combining different types of systems to
provide hybrid solutions, both on new and existing sites (green and brown field
development).
FAST/TOOLS has a truly User Environment. All the workflow processes, business logic,
and database links were designed after careful studies both technical and ergonomically.
Its built to work autonomously in a web-based user environment and can be extended
with new applications. Web-based applications can easily access legacy data on other
platforms. Typically interactive, the application accepts input from the web user,
processes the input, and displays the results. Information is stored on BuildLinks servers
and the access is obtained via secure logins.
Applications and process information can be rapidly deployed and is easily maintained
centrally on the server. This so called zero deployment means that client applications
can be run from any web-browser and the users always get the most recent version of an
application. There is no need to manage licenses and software installations on the client
side and no application files need to be copied over and no communication configurations
need to be setup. Benefits include faster application deliverys increased IT productivity,
and widely accepted technology.
Other benefits of a user environment are:
Information can be accessed anywhere an Internet connection is available.
The information is real-time (no waiting time for critical information).
The information is more secure than it would be on a personal computer.
Upgrades containing new functions and enhancements are free and automatically
deployed there is no need to manually install software or license keys.
The FAST/TOOLS Web HMI consists of a Web HMI Server and a Web HMI Client
component that can either run separate from the FAST/TOOLS Server or be installed
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altogether with the FAST/TOOLS Server environment on a standalone node. Installing
the Web HMI Server on a separate node has the advantage that load can be shared
between the FAST/TOOLS Server and Web HMI Server.
FAST/TOOLS has a true client/server architecture, which is not limited to stand-alone
stations, and allows for distributed functionality. Front-end Servers give the possibility to
reduce the load on the SCADA Server by preprocessing data on remote locations and
passing through only relevant data. Configuration of these stations is stored on the
SCADA Server and is automatically deployed to the Front-end Servers. There is no need
for the engineer to visit the remote locations. SCADA and Front-end Servers can run one
or more I/O-drivers per node, e.g. a configuration could be an application running up to
70 I/O-drivers at the same time on one node, using for example only three network
connections available to connect to the 70 remote PLC/RTU devices. Where system
availability is a prime issue FAST/TOOLS can be configured to run in a redundant
configuration. Several redundancy concepts are available as a standard, illustrating the
flexibility of FAST/TOOLS. Examples are dual or triple server configurations, redundant
networks between the SCADA system servers and clients and/ or between SCADA
system servers and PLCs, RTUs, etc. With the exception that Front-end servers can only
be configured as a single server entry.
2.9 STARDOM
The STARDOM is the first system rolled out as a Yokogawa network-based control
system (NCS). An NCS proposes an architecture designed for the e-business era. The
increasingly common business practice of E-commerce provides an environment for
swiftly responding to changes in market demand in many industries. However, these
industries have now come to require a new system architecture for industrial control
systems. An NCS meets these emerging new requirements and offers high flexibility to
build a superior control system, i.e., a system befitting each users purpose.
The STARDOM is an NCS that embodies Yokogawas expertise in the industrial
automation market. Reliability, operability, flexibility, scalability, and other keys for
implementing functionality in an industrial control system are all featured in the
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STARDOM. The STARDOM allows users to enjoy the merits of important information
technologies such as, Web, Java, and security as part of the system. The use of a variety
of these ITs allows an open system to be configured more flexibly to suit each users
intended application e-commerce, supply chain management without having knowledge
of particular systems.
Besides, the STARDOM is a Commercial Off-The Shelf (COTS) system, thus slashing
the total costs of ownership. Also offered by the STARDOM is a new way of operation
and monitoring using a VDS Viewer as the human interface. This means that whatever
the operation and monitoring task, it can be performed anytime, anywhere with a thin
client as a COTS platform. Its control network can be any TCP/IP-based network such as
an Ethernet, fiber distributed data interface, or wireless satellite communication network,
and a variety of communication protocols in the control layer can be combined with the
system.
The STARDOM consists of the following highly independent components:
FCN (an acronym of Field Control Node) is a modulus controller assembled with CPU,
I/O, and other modules as necessary. It supports a variety of I/O modules, has superb
expandability, and can build a highly reliable system with its power supply, CPU, and
control network duplexed.
FCN-RTU (Low power Autonomous controller) is a modulus controller assembled with
a CPU module with built-in analog,digital I/O,communication ports. Up to eight arbitrary
I/O module can be installed (with long base module). FCN-RTU can be used wide
temperature range and high altitude place.
FCJ (an acronym of Field Control Junction) is an allin-one controller with a built-in I/O
interface, ideal for installing inside machine equipment as well as configuring a
distributed system. Besides, its control network can be duplexed.
2.10 VDS Versatile Data Server Software: VDS is a software package that runs under a
Windows operating system and implements a Web-based human machine interface, OPC
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server functions, data acquisition from a variety of controllers and devices, and historical
data management.
Other features include:
Graphic windows for operation and monitoring, are enabled by HMI server and HMI
client (VDS Viewer) mechanism.
Object-oriented, COM/DCOM-enabled data sever
Optionally duplexed network that links autonomous controllers with readily available
Ethernet devices.
Link with not merely autonomous controllers of the STARDOM but also Yokogawa
FA-M3 controllers and other manufacturers controllers
A wealth of optional packages such as Report Package and Trend Package
Components practically usable on Visual Studio, including graphic components and
multi-task application development supporting components
2.11 Application Portfolios
Application Portfolios are packages in which many years of Yokogawas expertise in
control system configuration are packed, and provide application libraries of broad ranges
of software parts from small parts to those covering an entire plant control application.
Application Portfolios increase efficiency of all engineering stages from designing,
coding, debugging, to startup. In addition to portfolios containing elementary software
parts for control and communication functions, collections of control functions tailored to
a specific process or equipment are offered as Application-specialized Portfolios.

CHAPTER-3
TASKS PERFORMED
As an intern I was appointed as a Project Trainee in a project named Design, Supply,
Installation, Testing & Commissioning of SCADA & APPS System, PLC System,
Telecommunication System for Naharkatiya - Barauni Pipeline.

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The objective of the project is to design the system functionality in all respect to full-fill
the requirement of contractual specification of the project. The functional capabilities of
the system, Hardware and Software used for communication and data flow, flow
relationships among the various components and interfacing with HMI, sub-systems and
instrumentation interfaces are described in the document. The document also includes
communication protocols, system redundancies, General arrangement of various
equipment system configuration diagrams, and interface with the OIL supplied
communication system and technical literature of all equipment. This report describes
how the functional requirements for this new OIL-NBPL SCADA system, as specified in
the OIL documentation, are implemented by Yokogawa.
This Design Specification covers the conceptual design of:

SCADA Application For Pipeline Monitoring, Control And HMI, Namely,

Fast/Tools

Engineering Tool For Logic Development.

Overall System Architecture And Network Drawings

Overall System Hardware Design.

Communication Between Stations.

External Interface Descriptions.

Design, supply, installation and commissioning of SCADA and Station Control Centre
facilities & associated Instrumentation system of the proposed pipeline from Naharkatia
to Barauni along with branch pipelines from intermediate points at various locations as
described:

Noonmati and Jorhat will be the Master and Emergency Control Stations (SMCS

& ECS) of SCADA system for the Naharkatiya-Barauni Crude Oil Pipeline.
Noonmati is designated as SCADA Master Control Station(SMCS) while Jorhat is

configured as Emergency Control Station (ECS).

The entire data of NBPL stations including RS / RT / PS will be controlled from

Local PS / SMCS / ECS.

SMCS at Noonmati will be interfaced with the ECS at Jorhat for synchronization
of the data between Server to Server.

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To ensure effective and reliable control, management and supervision of the pipeline, the
entire pipeline network is envisaged to be monitored and controlled from SMCS
consisting of SCADA & APPS system located at Noonmati (PS-5) and ECS at Jorhat(PS3).To enhance the availability of SCADA system, redundant data connectivity through
RTUs & Local Server (PS-1, PS-2, PS-3, PS-4, PS-5, PS-8, PS-10 and TPS) and RWS
(PS-6,PS-7,PS-9 & NRL RT) distributed along the pipeline is envisaged between SMCS
and ECS over the following paths:

100 Mbps Redundant Ethernet LAN provided for SCADA servers over SDH
system.

100 Mbps Ethernet LAN NJ provided for database and events synchronisation
Between SMCS and ECS over SDH system.

6 Mbps Backup communication link over Leased Line (LL-2) between PS-1 &
PS- 10{back up link required in case OFC link failure}.

4 Mbps Backup communication link over Leased Line (LL-1) between SMCS
(PS-5) and ECS (PS-3) {back up link required in case OFC link failure}.

40 Mbps Redundant Ethernet LAN provided by Fiber optic communication for

RTU communication.

40 Mbps Redundant Ethernet LAN provided by Fiber optic communication for

RWS communication.

For intermediate monitoring and control two nos. of Dual redundant Local Server and
Station PLC Workstations will be provided under password control for the following
identified locations :

Naharkatiya Pumping Station (PS-1)

Tengaghat Pumping station (PS-11).

Moran Pumping Station (PS-2).

Jorhat Pumping station (PS-3)(ECS).

Sekoni Pumping station (PS-4).

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Noonmati Pumping station (PS-5) (SMCS).

Sonapur pumping station(PS-8).

Barauni pumping station ( PS-10).

For intermediate monitoring and control, SCADA - HMI & APPS Remote Workstations
will be provided (under password control) at the following identified locations :

Bongaigaon pumping station ( PS-6)

Madarihaat (PS-7)

Dumar (PS-9)

Numaligarh Refinery terminal (NRT)

To monitor various process, electrical equipment status, Cathodic Protection and

control, SCADA, PLC and RTUs are considered at following locations:

Naharkatiya Pumping Station (PS-1)

Tengakhat Pumping station (PS-11)

Moran Pumping Station (PS-2)

Jorhat Pumping station (PS-3) (ECS)

Sekoni Pumping station (PS-4)

Noonmati Pumping station (PS-5) (SMCS)

Sonapurpumpingstation(PS-8)

Barauni pumping station ( PS-10)

To monitor various process, electrical equipment status, cathodic protection and

remote control from SCADA, RTU based system are considered at following
locations:

Bongaigaon Pumping station( PS-6)

Madarihat Pumping station ( PS-7)

Dumar pumping station ( PS-9)

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Unmanned Repeater station (Sectionalising valves) stations - 16 Nos.

Refinery terminals- 4 nos. (Digboi, NRL, Bongaigaon and Barauni)

For reliable and efficient operation of pipeline, APPS system has been considered
long with Leak Detection & location at all conditions through APPS for the complete
NBPL pipeline project, supplementary APPS modules for enhancing the pipeline
operational aspects has also been considered.
My Section of work:
1.Trace P&IDs.
2. Functional Schematics.
3. Trace System Configuration.
4. Interconnection Cable Schedule.
5.Front loading & Nest loading.
6.POKEYOKE.
7.Project Documentation.

1.P&ID(Piping and Instrumentation Diagram)

Piping and Instrumentation Diagrams or simply P&IDs are the schematics used in the
field of instrumentation and control (Automation) The P&ID is used to by field techs,
engineers, and operators to better understand the process and how the instrumentation is

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inter connected.Most industries have standardized the symbols according to the ISA
Standard S5.1 Instrumentation Symbol Specification.
A piping and instrumentation diagram/drawing (P&ID) is defined by the Institute of
Instrumentation and Control as follows: A diagram which shows the interconnection of
process equipment and the instrumentation used to control the process. In the process
industry, a standard set of symbols is used to prepare drawings of processes. The
instrument symbols used in these drawings are generally based on International Society
of Automation (ISA) Standard S5.
The primary schematic drawing used for laying out a process control installation.
P&IDs play a significant role in the maintenance and modification of the process that it
describes. It is critical to demonstrate the physical sequence of equipment and systems, as
well as how these systems connect. During the design stage, the diagram also provides
the basis for the development of system control schemes, allowing for further safety and
operational investigations, such as a Hazard and operability study commonly pronounced
as HAZOP.
For processing facilities, it is a pictorial representation of

Key piping and instrument details

Control and shutdown schemes

Safety and regulatory requirements

Basic start up and operational information

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Figure.1- Legends

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Fig.2- P&ID for PS-6

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Fig.3- P&ID for PS-6

Fig.4Surge
tank and Transfer pumps at PS-6
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2.FUNCTIONAL SCHEMATICS: A carefully planned schematic diagram will simplify
the study and servicing of the equipment. Whereas a conventional schematic merely
shows the electrical components and how they are connected, a functional schematic will
place these parts on the drawing in such a way as to delineate the circuits they build. It is
expanded by considering major equipments as electrical structures built of circuits, and
by treating components as having functions to perform in their circuits. These points are
illustrated with functional drawings. Ideas and techniques are suggested which can make
schematic diagrams more lucid. Below is the P&ID and Functional Schematics for one
pump station.

Fig.5Schematic for Analog input with IS barrier without interlock

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Fig.6- Functional Schematic for Differential Pressure Transmitter

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Fig.7
Functional Schematics for Voting System

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Fig.8 Functional Schematics for Electric Heater

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Fig.8- Functional Schematic for Electric Heater

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Fig.9 Functional
Schematic for
Motor Operated
Valve

3. SYSTE
M

CONFIGURATION
Fig.10- System configuration-PS3-Jorhat
4.ETHERNET CABLE SCHEDULE:
Below Figure.11 shows the Ethernet Cable Tags for pump station 3 named Jorhat. In this
schedule all the Ethernet cables are traced between all servers, switches, HMIS,
Controllers etc.,

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Fig.11- Ethernet Cable Schedule for PS3

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Ethernet Cable Schedule for PS3

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5.FRONT LOADING AND NEST LOADING
The Yokogawa System consists of a minimum of one field control station and a human
interface system.
In an FCS( Field control station) there are different nodes consisting of different cards to
which the inputs are connected and outputs are taken out after processing. The selection
of cards and the number of cards in each node depends on various parameters.
The selection of these cards and the loading of them in each node taken into account of
all the parameters is called NEST LOADING. It depends on whether the input or output
is digital or analog, voltage or current, coming from a RTD or thermocouple or whether
its a field-bus input etc and the CPU loading.

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Fig.12 Front loading for PS-6

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Fig.12 Front loading for PS-6

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6. POKEYOKE- An Efficient tool designed by Yokogawa to produce Nest-Loading
Reports.

Fig.13- IO list Dashboard

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Fig.14- Station Table

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Fig.15- Nest Loading Wizard.

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Fig.16- Wiring Details

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Fig.17- Document Map
POKEYOKE follows below steps to produce Nest Loading reports:
As shown in Fig.13- IO list Dashboard is the first step in which the IO list is imported as
an input. Gamma IO list is produced. Spare estimation is also done in this step along with
Junction Box Schedule.
In Station Table all details about each pumping station is entered as shown in Fig.14
which is the second step.
In the third step the front loading which was designed for the Analog and Digital Cards is
placed along with all its specifications as shown in Fig.15 named Nest Loading Wizard.
Fig.16 gives us the Wiring details which is the last step of this tool. This step also
includes importing the Wiring Table and Bill of Material.
Fig.17- Document Map gives the details of all the documents prepared, its revision
number, revision date and about its approval status.

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CHAPTER-4
REFLECTION NOTES
Specific technical outcomes:
1.Learnt how to trace the wiring of cabinets of all pump stations. Below is the
General Arrangement for RTU system cabinet at Pump Station-6.
Types of Cabinets:

System Cabinet.
Server Cabinet
Analog Marshalling Cabinet
Digital Marshalling Cabinet
PDB Cabinet

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Fig.18 General Arrangement
Fig.19 Internal Arrangement

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Fig.20 Internal Power Wiring 24V DC

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Fig.21 Internal Power Wiring 230V AC UPS

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Fig.22 Internal Power Wiring 230V NON-AC UPS

Fig.23 Panel Bill of Material
Outline :
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Panel / Console wiring for this project is subjected to clients visual Inspection to confirm
that wiring done is in accordance with terminal Arrangement and Panel/Console
drawings.
Objective : The purpose of this test is to verify that the following are in accordance with
the approved wiring drawings.
Reference :
1. GA/IA Drawings of Panel/Console.
2. Panel Wiring Drawings.
3. Typical Loop Drawings
Procedure : Visually check that each Panel/Console wiring based on above objectives
and verify that each Panel wiring is in order.
Criteria : Each I/O configuration should confirm in accordance with the Nest loading.
2.Participated in ordering of materials for the project i.e., raised MPR(material
purchase requisition).

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Fig.24MPR for
Network
Devices

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Fig.24- MPR for Network Devices

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3.Loop Check of Cabinets at all pump stations during Pre-FAT and FAT.
The Factory Acceptance Test (FAT) will be conducted in accordance with the test
procedures detailed in this document. The scope of this FAT at YIL, BANGALORE
would include hardware check, visual checks on workmanship and functional tests in
accordance with the FAT documents and to clear the equipment for delivery to site.
The Factory Acceptance Test consists of 4 main parts namely, inspection of:

Hardware.
System Software.
SCADA System Application.
Loop Checking.

The system shall be energized at least 30 days before FAT. The loop checking of all I/Os
shall be carried out as per the procedure elaborately explained in this document. This
ensures the hardware loop integrity from the marshalling cabinets to the graphics. This
also takes care of proper functioning of Terminal Boards, Relays, pre-fabricated cables,
nest loading and configuration of software blocks in the system. The controllers shall not
be put in to simulation (test function) mode while these checks are carried out.
Subsequent to the successful completion of above activity, the controllers shall be put in
test mode for testing of loops and logics.
Outline :
I/O configured for this project is subjected to clients inspection to confirm that Hardware
& Software configurations are in accordance with the Nest loading.
Objective : The purpose of this test is to verify that the I/O configuration is done as
per nest loading.
Reference :
1. Front Loading and Nest Loading
2. Typical Loop Drawings RTU
3. Functional Schematics
Procedure :
1. For Analog input 4-20mA shall be injected with the help of calibrator across the rack
terminals. The Value of the input on the Face plate shall be noted (5 Point Check
0%,25%, 50%, 75%, 100%).

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2. For Analog outputs tag value shall be forced from the face plate. The current is
measured using a calibrator. The analog signals shall be increased / decreased and
different readings to be noted.
3. For testing Digital Input loops, the signal will be simulated from the marshalling
terminals & the status change is observed in face plate.
4. For testing Digital Output loops, the tag shall be forced from the faceplate and the
voltage/Continuity across the marshalling terminals shall be checked by using the Multimeter.
5. 50% of the loops per card will be tested, however 100% loops will be tested during Pre
FAT.
Criteria : Each I/O configuration should confirm in accordance with the Nest loading.
Test Record Ref : Loop Check sheet.
4.System configuration Check
Outline : The various systems and the components of the project are connected as per the
client specification which forms part of the system configuration.
Objective : the purpose of this test is to verify that all the systems are connected in line
with the overall system configuration.
Procedure :
1. Ensure that all the RTU controllers are connected as per the configuration
2. Ensure that all the HMI stations are connected as per the configuration
3. Ensure that all the network components are connected as per the configuration
4. Ensure that all the printers are connected as per the configuration
5. Ensure that the network connectivity between various systems is in order.
Criteria : the system connectivity is in line with the approved system configuration.

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5.BOM(BILL OF MATERIAL) check
Outline: All hardware & software for this project is subjected to clients visual inspection
to confirm that all components & accessories model no. And quantities are in accordance
with the BOM.
Objective : the purpose of this test is to verify the model no. And quantity of all
hardware, software and accessories.
References:
1. Bill of material
2. Commissioning & warranty spares
3. Hardware FDS
Procedure:
1. Visually inspect each component based on the above objectives and verify that each
component is in order.
2. Verify whether the required software is loaded in the respective Stations.
3. Verify spares and spare space as per the approved project philosophy.
4. Verify the hardware specifications of servers, workstations, laptops as per the approved
datasheets.
Criteria : All component & accessories model no. & quantity should as per the BOM.
6. Front loading check
Outline :
All Remote Terminal Unit (FCN), I/O Nodes and Modules are defined during engineering
and the position & quantity of each item installed in the respective cabinets are of utmost
importance.
Objective :
The purpose of this test is to verify that all RTU, I/O Nodes and modules are correct in
quantity and that each item is installed in the right position.
References : Front/Nest Loading-RTU
Procedure :
1. Visually check that each Node Interface Unit (NIU) is installed in the right position
and correct in quantity.
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2. Visually check that each I/O Nest is installed in the right position and correct in
quantity.
3. Visually check that each I/O Module is installed in the right slot and correct in
quantity.
4. Visually check that all labeling is in order.
Criteria : The locations of the RTU, I/O Nodes & Modules are in accordance with
the Front / Nest Loading.
Specific Non-Technical outcomes
Personally Experienced the following while working at YOKOGAWA.

A resourceful, creative, internationally-oriented work environment.

Independence and considerable personal responsibility.

A flat organization with short lines of communication.

A continuous process for learning, development and growth.

A talented team of professional, highly-motivated colleagues.

Making the Most of my Experience.

Internship is an opportunity to achieve personal and professional goals, and learn new
ideas and skills. In addition, this experience is a great way to network.
Being positive, enthusiastic, and a problem-solver.
Be realistic and be willing to take on less-than-glamorous tasks.
Not every assignment will lead to glory, but the task may be important to the employer.
Being attentive and giving 100% will be strong indicators of your work ethic and will
lead to greater responsibility.
Project comes along that interests you
Demonstrate organizational skills and initiative. Begin to develop new levels of
responsibility by noticing the tasks around the office that need to be done, and asking the
supervisor if you can take on the challenge.
Asking questions, but know when to listen and observe.
In the beginning, noticed processes or procedures that do not seem to make sense.
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Be willing to accept feedback and criticism.
This is one of the hallmarks of a true professional.
Keeping the supervisor informed.
If you need more time on a project, ask for it. Keep the lines of communication open.
Seeking out mentors and learning from colleagues.
Make a point to learn business etiquette.

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REFERENCES AND ANNEXURES
1. http://www.yokogawa.com/in/technical-library/
2. https://en.wikipedia.org/wiki/Yokogawa_Electric

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