Replacement of Pneumatic Field Controllers and Providing the Control of Process

Variables in DCS

11 Unit DCS I/O Count

a. Closed Loop Signals : 12 Nos.

b. Open Loop Signals : 11 Nos.

21 Unit DCS I/O Count

a. Closed Loop Signals : 10 Nos.

b. Open Loop Signals : 04 Nos.

12 Nos. & 10 Nos. of Closed loop signals are for Local Controllers Installed in 11
& 21 Unit and 11 Nos. & 04 Nos. open loop signals are for the Motor Ampere
Indication, presently available only in the field.

Other field Instruments required:

a. Pressure Transmitters : 13 Nos.

b. Differential Pressure Transmitters : 05 Nos.
c. Thermocouple : 04 Nos.
d. Current to pneumatic convertor : 23 Nos.
e. Current Transducer : 14 Nos.
f. Branch cable
i. Single core (1P * 1.5sq.mm) : 5000 m
ii. Single pair ‘J’ Type cable : 500 m
g. Multicore cable
1. ‘J’ Type cable 12 * 20 AWG : 500 m
2. Signal cable 12 * 0.5 : 1000 m
h. Junction Box 12IN* 1OUT : 06 Nos.
To Accommodate the Closed Loop signals and Open Loop Signals in the
present DCS following DCS items are required as no spare channels for
Closed loop and open loops signal are available in FCS 0201 ( 11 Unit ) &
FCS 0202 ( 21 Unit ). In FCS 0203 ( 11 Unit ) & FCS 0204 ( 21 Unit ) only
one node is presently available which is also not having any spare channels.
So, to accommodate the above signals , a 2nd node is to be add in FCS
0203 & FCS 0204. For that below DCS items are required :
List of DCS Items for FCS 0203 ( 11 Unit )
a. Node Interface Unit ( ANB10D-410 CU2N ) : 01 No.
b. Power supply ( PW 481 ) : 02 Nos.
c. ESB Bus Interface Module ( EC 401 -10 ) : 02 Nos.
d. Node Bus Interface Module ( SB 401 ) : 02 Nos.
e. ESB Bus cable ( YCB301-C100 ) : 02 Nos.
f. Analog I/O card ( AAB 841 ) : 04 Nos.
g. Analog Input Module ( AAV 141 ) : 04 Nos.
h. Cable for AAB 841 ( KSI * 10*A ) : 04 Nos.
i. Cable for AAV 141 ( KSI * 10*A ) : 02 Nos.
j. Cable for ADV 151 ( AKB 331 10*A ) : 01 Nos.
k. Marshalling cabinet ( 1200(W)*800(D)*2120(H) ) : 01 Nos.
( Details of marshalling cabinet is with attached annexure )
List of DCS Items for FCS 0204 ( 21 Unit )
l. Node Interface Unit ( ANB10D-410 CU2N ) : 01 No.
m. Power supply ( PW 481 ) : 02 Nos.
n. ESB Bus Interface Module ( EC 401 -10 ) : 02 Nos.
o. Node Bus Interface Module ( SB 401 ) : 02 Nos.
p. ESB Bus cable ( YCB301-C100 ) : 02 Nos.
q. Analog I/O card ( AAB 841 ) : 04 Nos.
r. Analog Input Module ( AAV 141 ) : 04 Nos.
s. Cable for AAB 841 ( KSI 10*A ) : 04 Nos.
t. Cable for AAV 141 ( KSI 10*A ) : 02 Nos.
u. Cable for ADV 151 ( AKB 331 10*A ) : 01 Nos.
v. Marshalling cabinet ( 1200(W)*800(D)*2120(H) ) : 01 Nos.
( Details of marshalling cabinet is with attached annexure )
Tag List Of Closed Loop Signals

11 Unit Tag List :

Sl.No. Tag No. Description Range

1 11 PIC 306 P-1 A/B Seal Flush Pr. Control 0-16 Kg/cm2
2 11 TIC 55A P-1 A Lube oil Temp. Control 0-150 Deg C
3 11 TIC 55B P-1 B Lube oil Temp. Control 0-150 Deg C
4 11 PIC 307 11 P-37 Suction Line Pr. Control for P-2 A/B Seal Pressure 0-16 Kg/cm2
5 11 LIC 134 E-3 Condensate Outlet Line 0-100 %
6 11 LIC 145 E-14 Condensate Outlet Line 0-100 %
7 11 LIC 143 E-15 Condensate Outlet Line 0-100 %
8 11 PIC 311 LS Tracing Line Pr. Control 0-5 Kg/cm2
9 11 PIC 210 P-11 Discharge Line pressure Control 0-250 Kg/cm2
10 11 PIC 5.1 TK-1 Gland Steam Pr. Control ( Split Range ) 0-1 Kg/cm2
11 11 PIC 1A 11 P-2 A Lube oil Pr. Control 0-10 Kg/cm2
12 11 PIC 1B 11 P-2 A Lube oil Pr. Control 0-10 Kg/cm2

21 Unit Tag List :

1 21 PIC 306 P-1 A/B Seal Flush Pr. Control 0-16 Kg/cm2
2 21 TIC 55A P-1 A Lube oil Temp. Control 0-150 Deg C
3 21 TIC 55B P-1 B Lube oil Temp. Control 0-150 Deg C
4 21 PIC 307 21 P-37 Suction Line Pr. Control for P-2 A/B Seal Pressure 0-16 Kg/cm2
5 21 LIC 134 E-3 Condensate Outlet Line 0-100 %
6 21 LIC 145 E-14 Condensate Outlet Line 0-100 %
7 21 LIC 143 E-15 Condensate Outlet Line 0-100 %
8 21 PIC 311 LS Tracing Line Pr. Control 0-5 Kg/cm2
9 21 PIC 5.1 TK-1 Gland Steam Pr. Control ( Split Range ) 0-1 Kg/cm2
10 21 PIC 1A 11 P-2 A Lube oil Pr. Control 0-10 Kg/cm2
11 21 PIC 1B 11 P-2 A Lube oil Pr. Control 0-10 Kg/cm2
Tag List Of Open Loop Signals

11 Unit Tag List :

1 11 II 24A 11 P-24A Ampere Indication 0-1 Amp.

2 11 II 24B 11 P-24B Ampere Indication 0-1 Amp.
3 11 II 27A 11 P-27A Ampere Indication 0-1 Amp.
4 11 II 27B 11 P-27B Ampere Indication 0-1 Amp.
5 11 II 10A 11 P-10A Ampere Indication 0-1 Amp.
6 11 II 10B 11 P-10B Ampere Indication 0-1 Amp.
7 11 II 15A 11 P-15A Ampere Indication 0-1 Amp.
8 11 II 15B 11 P-15B Ampere Indication 0-1 Amp.
9 11 II 16A 11 P-16A Ampere Indication 0-1 Amp.
10 11 II 16B 11 P-16B Ampere Indication 0-1 Amp.

21 Unit Tag List :

1 21 II 24A 21 P-24A Ampere Indication 0-1 Amp.

2 21 II 24B 21 P-24B Ampere Indication 0-1 Amp.
3 21 II 27A 21 P-27A Ampere Indication 0-1 Amp.
4 21 II 27B 21 P-27B Ampere Indication 0-1 Amp.

Estimate for the DCS Component’s required :

DCS Item Required is as per the DCS List.

Node Interface Unit ( ANB10D-410 CU2N) 2 Nos.
Power Supply ( PW 481 ) 4 Nos.
Node Bus Interface Module ( SB 401 ) 4 Nos.
1 ESB Bus Interface Module ( EC401-10 ) 4 Nos.
ESB Bus Cable ( YCB301-C100 ) 4 Nos.
Analog I/O Card ( AAB841 ) 8 Nos.
Analog Input Module ( AAV141 ) 4 Nos.
Cable for AAB841 ( KSI 10*A ) 8 Nos.
Cable for AAV141 ( KSI 10*A ) 4 Nos.
Cable for ADV151 ( AKB 331 10*A ) 2 Nos.
2 Marshalling Cabinet ( 1200(W)*800(D)*2120(H) ) 2 Nos.
Approx . Cost of DCS Items including all Accessories in ( Rs ) 4500000.00
 Estimate for the field Instruments

Sl.No. Description Qty. Unit Cost Total Cost Remarks

Req.
Pressure Transmitter
Range : 0-16 Kg/cm2 - 04 Nos. 15 Nos. 30,000.00 4,50,000.00
0-10 Kg/cm2 - 04 Nos.
1. 0-5 Kg/cm2 - 02 Nos.
0-1 Kg/cm2 - 02 Nos.
0-250 Kg/cm2 - 01 Nos.
Spare - 02 Nos.
Differential Pr. Transmitter 08 Nos. 35,000.00 2,80,000.00
2. Range 0–2400 mm WC – 06 Nos.
Spare - 02 Nos.
Thermocouple with all accessories 2,000.00 12000.00
L : 150 mm - 04 Nos. 06 Nos.
3.
Spare - 02 Nos.
Type : ‘J’ Type Duplex TC
Current to pneumatic convertor 25 Nos. 45,000.00 11,25,000.00
4 – 20 mA to 0.2 - 1.0 Kg/cm2
4.
Qty : 23 Nos.
Spare : 02 Nos.
Current transducer 24 Nos. 8,000.00 1,92,000.00
0-1 Amp. To 4-20mA
5.
Qty : 14 Nos.
Spares : 10 Nos.
Cables
12 pair * 0.5 sq.mm – 900 m 1000m 400.00 4,00,000.00
6. 1Pair * 1.5 sq.mm – 4200 m 5000m 65.00 3,25,000.00
1Pair 16 AWG ‘J’ Type – 500 m Available
12 Pair 20 AWG ‘J’Type – 900 m Available

Junction Boxes
7.
12 IN / 1 OUT - 06 Nos. Available

Total Cost 27,84,000.00

DCS Items required for NODE Extension in existing system cabinet as node 2 , consisting of following items

System Item List

Comp No. / Domain /
SL No. Desciption Model No. Qty Remarks
Location Station
11 UNIT FCS 0203
1 110 / R1 02 / 03 Node Interface unit ANB10D-410 CU2N 1
2 110 / R1 02 / 03 Power supply unit for Node PW 481 2
3 110 / R1 02 / 03 Node bus Interface Module SB401 2
4 110 / R1 02 / 03 ESB Bus Interface Module EC401-10 2
5 110 / R1 02 / 03 ESB Bus Cable YCB301-C100 2
6 110 / R1 02 / 03 8+8 Channel Analog Input/Output Module ( REDUNDANT ) AAB841 4 2 + 2R
7 110 / R1 02 / 03 16 Channel Analog Input Module AAV141 2
As per attached
8 204 02 / 03 Marshling cabinet -1200(W)*800(D)*2120(H) WMC12-FERRC
1 annexure
21 UNIT FCS 0204
1 115 / R1 02 / 04 Node Interface unit ANB10D-410 CU2N 1
2 115 / R1 02 / 04 Power supply unit for Node PW 481 2
3 115 / R1 02 / 04 Node bus Interface Module SB401 2
4 115 / R1 02 / 04 ESB Bus Interface Module EC401-10 2
5 115 / R1 02 / 04 ESB Bus Cable YCB301-C100 2
6 115 / R1 02 / 04 8+8 Channel Analog Input/Output Module ( REDUNDANT ) AAB841 4 2 + 2R
7 115 / R1 02 / 04 16 Channel Analog Input Module AAV141 2
As per attached
8 214 02 / 04 Marshling cabinet -1200(W)*800(D)*2120(H) WMC12-FERRC
1 annexure
Accesories
1 Cable for Analog Input/output card ( AAB841 ) KS1 10*A 4
2 Cable for Analog Input card ( AAV141 ) KS1 10*A 4
3 Cable for Digital Input card ( ADV151 ) AKB 331 10*A

Note : These two Nodes will be Installed in the existing system cabinet as second node in FCS 0203 & 0204 respectively
 QTY
Sl.No. ABBREVIATION ITEM DESCRIPTION MAKE/MODEL REMARKS
FRONT SECTION
01 PT POWER TERMINATORS ( Power TB's) PHOENIX 04
02 MM MINIATURE CIRCUIT BREAKER MERLIN CERIN 02 6A
03 PSU1 & 2 POWER SUPPLY UNIT( 27A, 24V) COSEL 02
04 DRI 1 & 2 DIODE O— RINC M ODULE(SOAMPS) PARAMOUNT 02 30A
05 FM1~2 MINIATURE CIRCUIT BREAKER MERLIN GERIN 02 32A
06 BB1 BUS BAR YIL STD 02
07 FT1 MOTHER BOARD FOR AI/AO SIGNALS MB-AIO16V-KS1 02
08 FT2~3 MOTHER BOARD FOR AI SIGNALS MB-AI16V-KS1 02
09 AT1 ALARM TERMINALS PHOENIX/MTK— P/P 04
10 FFTB1 FUSE TERMINAL BLOKS PHOENIX 24 24V DC WITH LED
11 FZ1~4 DISCONNECTING TB'S PHOENIX 200
12 Ec CABINET EARTH 01
13 DSF DOOR SWITCH FRONT 01
14 TLF TUBE LIGHT FRONT PHILIPS 01
15 FAN 1 & 2 COOLING FANS FRONT 02
16 FILTER 1 & 2 AIR FILTER FRONT RITTAL 02
17 Esh SHIELD EARTH YIL STD 02
REAR SECTION
01 BB2 BUS BAR 02 16A
02 FFTB1 FUSE TERMINAL BLOKS PHOENIX 24 24V DC WITH LED
03 FT1 TERMINAL BOARD FOR DIGITAL I/P SIGNALS YAED5D 01
04 FR1~32 RELAYS 24v DC , 2 NO & 2 NC IDEC 32
05 TR01~10 TRANSDUSER ( 0-1AMP TO 4-20mA ) ABB 12
06 FFTB2 FUSE TERMINAL BLOKS PHOENIX 100 220V DC WITH LED
07 Ec CABINET EARTH STD 01
08 DSR DOOR SWITCH REAR YIL STD 01
09 TLR TUBE LIGHT REAR PHILIPS 01
10 FAN2 COOLING FANS REAR SUNON 02
11 YMRPTB *A POWER TERMIN AL FOR U TILITY SUPPLY 01
12 RCPT RECEPTACLE(240 VAC UPS) ROMA 01
13 PTI &1— PTI POWER TERMIN ATORS(POWER TB's] PHOENIX 08
14 MMI MINIATURE CIRCUIT BREAKER MERLIN GERIN 01
15 FILTER2 AIR FILTER REAR RITTAL 01
16 Esh SHILLD LARTH 01

Note : -1. All the Make/Model of the items described here should be of as described / or better / or as per existing YIL standards
2. Two marshelling cabinet of same specifications are required. Cabinate No. And description of the cabinet are as below...
a. 204F - # Analog Input Cabinet FCS 0203 ( 11 Unit )
204R - # Digital Input Cabinet FCS 0201 ( 11 Unit )
b. 214F - # Ana;og Input Cabinet FCS 0204 ( 21 Unit )
214R - # Digital Input Cabinet FCS 0202 ( 21 Unit )
 PANEL DETAILS

Sl.No. Panel description Standard

1 MAKE RITTAL STANDARDS ( 1200 * 800 * 2120 mm)
2 CONSTRUCTION BENT & BOLTED/WELDED
3 FRAME SHEETSTEEL MATERIAL
4 BASE FRAME 100*50*3.2 mm PLINTH CHANNEL
SPLIT DOORS - 2 mm TH. CRCA SHEET (RITTAL)
SIDE PANEL - 1.6mm TH. CRCA SHEET (RITTAL)
5 SHEET THICKNESS
TOP PANEL - 1.6mm TH. CRCA SHEET (RITTAL)
GLAND PLATES - 3mm TH. CRCA SHEET (RITTAL)
FRAME , FRONT & REAR DOORS , SIDE PANELS - HAVEL'S
6 COLOUR GREY - RAL(7035)
CHANNEL BASE - BLACK
7 CABLE ENTRY BOTTOM
8 GASKET POLYURATHENE GASKETTING
9 REMOVABLE GLAND PLATE 04 NOS
10 SIDE PANELS yes
11 STANDARD HANDLE SYSTEM WITH KEY & LOCK INSERT
12 HYLAM SHEET 5mm
13 PROTECTION GLASS IP54
14 PAINT THICKNESS 65 - 120 MICRONS
15 CRCA COLD ROLLED CLOSE ANNEALED