5 1 Electrical DCS and Measurement 20120531

Project:
Thailand 1
Project-No.:
605520
Drawing up:
5. Electrical, DCS and Measurement
5.1 Conceptual Formulation for electrical, instrumentation and DCS-system
page 1 of 15
5.1
Conceptual Formulation for Electrical and Instrumentation
5.1.1
General
The electric power distribution is designed to cover the load or consumption conditions of the
process plant during production, start-up or shut-down.
Instrumentation and control of the complete plant is designed to achieve a high standard of
process operations, according to the requirements of quality and safety.
All components fulfill the requirements in accordance to the local regulations and
international standards and regulations (VDE/IEC).
5.1.2
Climatic conditions (inside building)
The climatic conditions inside the building regarding the room for switch cabinets have to be
as follows:
Temperature not more than
35 C
(24-hour average 30C)
Relative air humidity not more than
95 %
(avoidance of sweating)
Regarding the control room the climatic conditions have to be as follows:
Temperature should be less than
30 C
Relative air humidity should be less than 85 %
(avoidance of sweating)
To realise these conditions it is necessary to install an air condition (control room and room
for switch cabinets).
5.1.3
Kind of power supply net
TN-S power supply net is confirmed by all parties as shown in figure 1.
Undervoltage trip signal comes from the Low Voltage Distribution to the DCS-system.
Figure 1: TN-S net will be used
Rev.: 0
605520_5_1_Electrical_DCS_and_Measurement_20120531.doc
Project:
Thailand 1
Project-No.:
605520
Drawing up:
page 2 of 15
5.1.4
Standard for electrical power supply

Voltage
380V / 220V
+10% and -10%.
Signal voltage
24V
Phases
3
Frequency
50 Hz
2% ( 1Hz).
5.1.5
Earthing, neutral and compensation of potential
Figure 2: Equipotential bonding system
Rev.: 0
Project:
Thailand 1
Project-No.:
605520
Drawing up:
page 3 of 15
As shown in the figure 2 generally there will be a connection to the steel construction of the
building also using technological steel constructions. Additional there should be one
connecting point in each room (each structural module) to connect to the building.
Equipotential bonding bands have to be installed inside of each switch cabinet. All shields of
the wire have to be connected there.
The customer give a guarantee to the earthing resistance of less than 1 Ohm using the steel
structure of the building.
5.1.6
Low Voltage Main Distribution
The low voltage main distribution, located adjacent to the transformer station,is fed from the
transformer with 0.4 kV and distributes the power to the MCC inverters, other subdistributions and switchboards. There are two transformers inside one power plant. In case of
any fault in one of the transformers there is an automatically switch over to the other one. The
automatically switch over time has to be confirmed by customer .
This switchgear system consists of input load breakers, with short current, thermal, and
undervoltage release.
The input feeder is equipped with the required power measuring devices, as well as power
consumption metering.
The reactive power compensation system may be integrated into the low voltage main
distribution, for a power factor of at least 0.90.
5.2
Conceptual Formulation for instrumentation
5.2.1
General
The instruments and the components are made for the industrial standards of the chemical
industry. All devices are carefully selected in accordance with the required task, the
environment and the classification of the process function.
Field mounted gauges indicate various process conditions such as pressure, temperature, flow,
concentration or level.
Important operating parameters will be measured by sensing elements and converted by
electronic transmitters into electric signals, which are connected to the local ET 200 control
cabinet in each floor. The local ET 200 control cabinets are connected with the central control
station via redundancy Profibus DP. Final elements, such as control valves or electrically
controlled devices, receive commands from local ET 200 control cabinets or the central
control station.
5.2.2
Signal level of sensors and actuators
The standard signal level of sensors is fixed by using 4 20mA. RTD elements only for
indication of temperature will be directly connected to the ET200.
The standard signal level of actuators is fixed by using 4 20mA.
Rev.: 0
Project:
Thailand 1
Project-No.:
605520
Drawing up:
page 4 of 15
The pneumatic auxiliary power supply will be instrument air with the conditions as follows:
Pressure
6 bar (g)
10%
Temperature
15 30 C
Dew point - 40 C (at normal pressure conditions)
The instrument air must be clean by dust and oil.
In each floor are several auxiliary air distributors.
5.2.3
Principles of measurement and vendor
Using the fluid code numbers there is a classification to the measuring method for the
measured variable as follows:
Fluid code
number
1210, 1220,
1310, 1400,
1410, 1610,
1630, 1640,
1910, 1920
Measured variable
Measuring method
Temperature
PT100 (cover tube)

Local gas pressure thermometers (cover tube)
Suspended body flow meter
Bypass / float level indicator / switch or
Level switch by tuning fork or
Radar / Microwave level transmitter
Boundary tube gauge (pressure gauge) only local
Pressure transmitter (screwed or flanged)
PT100 (cover tube)
Pressure transmitter with diaphragm or siphon
PT100 (cover tube)
Suspended body flow meter, differential pressure
flow meter
Boundary tube gauge (pressure gauge) only local
or Pressure transmitter (screwed or flanged)
PT100 (cover tube)
Level switch by tuning fork or
Pressure transmitter with diaphragm
PT100 (cover tube)
Mass flow meter, flow indicator
Displacer level transmitter or
PT100 (cover tube)
Mass flow meter
Radioactive level transmitter or
Pressure transmitter with diaphragm, flanged
Ultrasonic transmitter
Flow
Level
Pressure
2310, 2320
3110, 3120,
3910, 5010,
5030
Temperature
Pressure
Temperature
Flow
Pressure
3410, 9120
3420, 3421,
6410, 6420, ,
7010, 9210,
9250, 9211,
9220, 9221
8710, 8720
8730
Temperature
Level
Pressure
Temperature
Flow
Level
Pressure
Temperature
Flow
Level
Pressure
Concentration
Rev.: 0
Project:
Thailand 1
Project-No.:
605520
Drawing up:
page 5 of 15
Fluid code
number
8740, 9110
5610, 5620
8790
8750, 9130
Measured variable
Measuring method
Temperature
Pressure
Temperature
Level
PT100 (cover tube)

PT100 (cover tube)
Radioactive level transmitter or
Polymer melt pressure transmitter
PT100 (cover tube)
Local bimetallic thermometers (cover tube)
Suspended body flow meter or
Ultrasonic flow transmitter
p Pressure transmitter with diaphragm, flanged
Ultrasonic transmitter
PT100 (cover tube)
Bypass magnetic level indicator
Boundary tube gauge (pressure gauge) with
siphon, only local
Pressure
Temperature
Flow
Level
Pressure
9710, 9720,
9730, 9740,
9750, 9760
Concentration
Temperature
Level
Pressure
Rev.: 0
Project:
Project-No.:
Drawing up:
Thailand 1
605520
page 6 of 15
List of approved vendors for E&I devices

Instruments for flow measurement
1 flow
Rotameter, gas and fluid
15-100 Krohne
SS H250/ RR/ M9
22
nitrogen and water in:

Lactamstorage
Extraction / Drying
indication only local
http:/ /www.krohnemar.com/Metal_Cone.11106.0.html
2 flow
10-25
SS H250/ RR/ M9/ K1
12
nitrogen in Lactamstorage
indication only local, switch contact to DCS
3 flow
15-100 Krohne
SS H250/ RR/ M9/ ESK
60
nitrogen and water in:

Lactamstorage
Extraction / Drying
Poly / Recovery
indication local and DCS
4 flow
coriolis flow meter
10-50
Siemens
SS MASS2100
Polymerisation
Additives
with heated jacket and without heated jacked, http:/ /pia.khe.siemens.com/ index_sitrans_f_c_
nobr_mass_2100_di_3-40_nobr_-13907.htm
5 flow
Rotameter, gas
10-25
Krohne
SS DK37M
10
Additives
indication and control only local
6 flow
ultrasonic flowmeter
Panametrics
SS AT 868
Recovery
clamp on mounting
DCS
7 flow
orifice flowmeter
40-300
dosch Messaparate
GmbH
SS BLB 300
Diphyl heating System
indication DCS
8 flow
volumetric flowmeter
10
Bopp & Reuther
SS Miniflow
Additives
indication DCS
9 flow
volumetric flowmeter
10-50
Bopp & Reuther
SS batch OI
Additives

Krohne
10 flow
flow indicator
G1/ 4"
EGE-Elektronik GmbH
SS SC 440/ 5-A4-GSP
10
Additives
Extraction
11 flow
Pitot Tube Flow Measurement
500
INTRA-Automation
GmbH
SS ITABAR IBF-25-ID323
Drying
indication DCS
12 flow
vortex flowmeter
300
Krohne
SS OPTISWIRL 4070C
Drying
indication local and
http:/ /www.krohnemar.com/DK_37__Variable_Area_Flowmeter__
en.784.0.html
http:/ /www.gesensing.com/ products/ at868.ht
m
http:/ /www.doschgmbh.de/ products04_e/ products/ dpflowmeter
/ blborificeplatewithsingleborepressuretaps/
http:/ /www.burmt.de/ BURMTWWW/ prod.php
?lang=us&prod=Miniflow#Anzeige1
http:/ /www.burmt.de/ BURMTWWW/ prod.php
?lang=us&prod=OI#Anzeige1
http:/ /www.egeelektronik.com/en/products/search.php?Typ=S
C+440%2F5-A4-GSP
http:/ /www.intraautomation.com/pdf/ products/ introduction/en
/ introduction_itabar_en.pdf
http:/ /www.krohnemar.com/OPTISWIRL_4070C__Vortex_Durchflu
ssmessgeraet__en.11250.0.html
Instruments for level measurement

1 level
level switch
15-80
KSR Kuebler
SS Float switches
switch contact to DCS
2 level
magnetic fold down level
15-50
KSR Kuebler
SS batch BNA
16

Extraction / Drying
3 level
4 level
vibration level switch

radimetric level transmitter
15-80
VEGA
Endress & Hauser
SS VEGAVIB VB 63
Gammapilot M FMG 60
26
10
5 level
Displacer (buoyancy) level transmitter
80
Foxboro Eckardt
SS 144 LD
15
6 level
Guided level radar measurement
50-100 VEGA
SS Levelflex 66
18
7 level
Guided level radar measurement
50-100 VEGA
SS Levelflex 61
Rev.: 0
Extraction / Drying
Polymerisation
Additives
Extraction / Drying
Lactamstorage
Additives
Recovery
Extraction
Extraction
switch contact to DCS

indication DCS
http:/ /www.ksrkuebler.com/ website/ index.php?lang=en&load

=123
http:/ /www.ksrkuebler.com/ website/ index.php?lang=en&load
=236
http:/ /www.vega.com/en/849.htm
http:/ /www.endress.com/ corporate
http:/ /www.foxboroeckardt.com/products/144ld_en.html
Project:
Project-No.:
Drawing up:
Thailand 1
605520
page 7 of 15
Instruments for pressure measurement

Lactamstorage, Additives,
Recovery, Extraction, Diphyl indication only local
heating System
1 pressure
pressure gauge
G1/ 2"
Manotherm
SS RCh 100-3
55
2 pressure
pressure switch
G1/ 2"
Manotherm
SS RCh 100-3 with limit switch
15
3 pressure
membrane pressure gauge
G1/ 2"
Manotherm
SS RCh 100-3 with MDM 7210
4 pressure
membrane pressure transmitter
50
VEGA
SS VEGABAR 61
5 pressure
differential pressure transmitter
50
VEGA
SS VEGADIF 55
6 pressure
melt pressure transmitter
M18
Dynisco
SS MDT 462F-M18-50-15
10
Polymerisation
indication DCS
melt pressure transmitter with temperature sensor
M18
Dynisco
SS TDT 463F-M18-50-15
Polymerisation
indication DCS
110
7 pressure
Lactamstorage
Additives
Recovery
Lactamstorage
Additives
48
Recovery
Extraction / Drying
Lactamstorage
Additives, Polym.
100
Recovery
Extraction / Drying
Recovery
14
Extraction / Drying
http:/ /armaturenbau.com/ Datenblaetterpdf/ 1201-eng.pdf
gauge with Diaphragm Seal, indication only

local
indication DCS
indication DCS
http:/ /www.dynisco.com/products.aspx?FID=7
6&MID=468&lang=en
http:/ /www.dynisco.com/products.aspx?FID=7
6&MID=474&lang=en
Instruments for temperature measurement

1 temperature
bimetal thermometers
M18
Manotherm
SS TBiCh GEL 100mm
2 temperature
thermometer switch
M18
Manotherm
SS TSCh GEL 100mm with contact
3 temperature
PT 100 temperature
M18
Electrotherm
SS PT 100, Typ 348, Typ 357
4 temperature
safety temperature limiter
Jumo
STB
Lactamstorage
Additives, Polym.
Recovery
Extraction / Drying
Polymerisation
14
Lactamstorage
Additives, Polym.
190
Recovery
Extraction / Drying
indication only local
indication DCS
http:/ /www.electrotherm.de/catalog/ chapter3.

pdf
http:/ /www3.jumo.de/ pio/ JUMO/en_DE/ prd/7
0.1130/ temperature-monitor-limiter-andsafety-temperature-monitor-limiter-formounting-on-din-rail.html
Instruments for field analysis measurement

1 analysis
oxygen analyzer
G1/ 2"
AMSGmbH
SS AMS3160
Drying
2 analysis
dew point measurement
G 1/2"
DKSDresden
SS NP330 G
Drying
3 analysis
concentration analyzer
50
SensoTech GmbH
SS LiquiSonic
Recovery
Rev.: 0
http:/ /www.amsdielheim.com/english/ pat.html

http:/ /www.dksdresden.de/ html/ dewpoint.html
http:/ /www.sensotech.com/ cms/produkte0.ht
ml?&L=1
Project:
Thailand 1
Project-No.:
605520
Drawing up:
page 8 of 15
5.2.4
MCC and operation philosophy for electrical drives
The MCC are used for the power supply of all electrical consumers. They contain all required
outlets to consumers e.g. motors, heaters or compact units.
The MCC contain all required motor protection switches, circuit breakers, contactors,
transformers, frequency inverters etc. as well as the corresponding control loops.
The MCC room should be direct beside the central control room. There located also the fuse
switches for all electrical drives.
Motors with a rated power of up to 15 kW will be started directly on line. Above 15 kW are
used star/delta starters or electrical soft start devices.
Electrical drives with frequency inverter are direct connected by the Profibus DP via Y-Link
and communicate via Profibus DP with the central control station.
There are automatically and manually operation mode (see figure 3). Switching is possible
from the OS/ES stations. Additional it is necessary to check all technological and technical
conditions before starting electrical drives.
Figure 3: Face plates for operating the electrical drives
Rev.: 0
Project:
Thailand 1
Project-No.:
605520
Drawing up:
page 9 of 15
Manually operation for the electrical drives is possible as follows:

There will be local panels for electrical drives in the field. On this local panels there are 3
(three) push buttons and 1 (one) light (see figure 4).
-
STOP means one can switch off the drive and the button is always active
to switch on (START) it is necessary to select LOCAL Operation Mode on the
DCS face plate
only if the LIGHT is off one can switch on the drive
if the LIGHT is on there is an error or an interlock is active
QUIT is to reset all errors regarding this drive
Selected drives are as follows:

- all melt pumps
- all pumps for liquid Caprolactam and recovered Caprolactam
- pumps for extract water in the extraction and recovery
- selected pumps in the heating system
Figure 4: Local panel for selected electrical drives in the field
Rev.: 0
Project:
Thailand 1
Project-No.:
605520
Drawing up:
page 10 of 15
5.3
Conceptual Formulation for DCS-system
5.3.1
General
The central control room is located preferably close to the process plant. For the plant control,
a Distributed Control System (DCS), with a redundant main structure from a well known
expert manufacturer like Siemens (SIMATIC PCS7), is used. This is an advanced system, to
provide coordinated solutions of industrial automation.
The central control room is the operator area, a functional and representative room, the
operator workstations will be arranged, each for the control of the production line. The
operators will manage sequence control and plant interaction from these places.
Rev.: 0
Project:
Thailand 1
Project-No.:
605520
Drawing up:
page 11 of 15
5.3.2
Overall DCS Configuration
Figure 5: Schematic overview of DCS-configuration

There are 3 (three) Operation Stations (OS) and 1 (one) Engineering Station (ES) which are
located in the control room. Each station is able to act all functions. The OS/ES stations have
single CPU inside and accomplished in industrial standard. The system software for the
OS/ES stations should be Windows XP and for the server stations Windows 2003 Server.
Rev.: 0
Project:
Thailand 1
Project-No.:
605520
Drawing up:
page 12 of 15
There is a redundant Ethernet connection between each PLC and each OS/ES-station. This
Ethernet-Bus-system is arranged as a circle and if there is a cut of this circle the Ethernet
works as a line with all functions. This means redundancy of the Ethernet-Bus-system is
realised also.
There is a redundant Profibus system between ET200 and PLC.
There is failsafe PLC (S7-400F) where the safety-related signals (measuring point with Zfunction) are connected.
The customer provides the software for Siemens PCS 7 or PCS7 Asia, and application
software for OS/ES and the PLCs.
5.3.3
Redundancy concept
The DCS is provided by the control processor station in a redundant configuration (see
figure 5). In the redundant operation, both controllers execute identical programs. Output
results are compared and, if identical, the result is transmitted to the input/output modules. In
the case of a mismatch, both controllers go through diagnostic test routines to determine
which one has failed. Both controllers read the same messages from the local network, but
output messages are transmitted by only one of them.
5.3.4
Operating and monitoring philosophy of DCS
All informations from the process and the multifunctional controllers are concentrated at the
operator stations, arranged in the central control room.
An OS/ES workstation is a console, from which the operator can monitor and manage the
process. The Siemens system Simatic PCS7 offer the user (process engineer, operator,
manager, or maintenance engineer) menu-based and pictorial
guidance for all interactions with the system or the process. This makes the system easy to
learn and easy to operate. Menu bars provide fast access to informations.
Description of some attributes of operation on the monitor:
Inside each picture there are buttons to reach the next picture.
All monitor pictures can be print out using screen-shot function (see figure 6). All events can
be printed out by line printer. Default list can also be print out.
Using right side mouse click on measuring points opens a face plate. There is shown the trend
of the historical values (see figure 7).
Rev.: 0
Project:
Thailand 1
Project-No.:
605520
Drawing up:
page 13 of 15
Figure 6: Example for monitor layout
Figure 7: Example for face plate Trend
Rev.: 0
Project:
Thailand 1
Project-No.:
605520
Drawing up:
page 14 of 15
Using left side mouse click on measuring points opens another face plate. There is shown the
parameters of the control loop and the actual state of the control loop (AUTO or MAN) (see
figure 8) or only switch and alarm parameters for an indication measuring point (see figure 9).
Figure 8: Example for face plate Control loop
Figure 9: Example for face plate Indication

It is necessary to arrange a user structure with different rights. For an example ordinary
operators should not be able to change special parameters of control loops (parameters for
PID-controller).
Rev.: 0
Project:
Thailand 1
Project-No.:
605520
Drawing up:
page 15 of 15
5.4
Emerency Power Supply
An Uninterruptible Power Supply (UPS) covered unexpected supply failure.

UPS has to be installed for DCS-system only including Operating Stations, Engineering
Stations and PLC. There is no UPS for the power of the field instrumentation and drives. The
time for buffering has to be 30 minutes, the capacity 30 KVA and the nominal voltage 380 V.
The time to hold the signals from the PLC can be only in maximum 2 seconds. After the
duration of 2 seconds the drives will be switched off by PLC and has to be restarted manually.
5.5
Remote maintenance
To realise the remote maintenance for the PLC a internet connection is necessary. The
customer must ensure that the ES-station is connected with an Internet connection.
5.6
Measurement Point Lists
All measuring points will be provide in separate lists.

5.7
Alarm and Set Point Lists
All interlocks, alarms and set points will be provide in separate lists.
5.8
Electrical Power Consumer Lists
All electrical power consumers will be provide in separate lists.
Rev.: 0

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Project:

Conceptual Formulation for Electrical and Instrumentation

Climatic conditions (inside building)

Figure 1: TN-S net will be used

Standard for electrical power supply

Earthing, neutral and compensation of potential

Figure 2: Equipotential bonding system

Low Voltage Main Distribution

Conceptual Formulation for instrumentation

Signal level of sensors and actuators

Principles of measurement and vendor

PT100 (cover tube)

PT100 (cover tube)

5.1 Conceptual Formulation for electrical, instrumentation and DCS-system

List of approved vendors for E&I devices

Rotameter, gas and fluid

nitrogen and water in:

indication only local

Rotameter, gas and fluid

SS H250/ RR/ M9/ K1

indication only local, switch contact to DCS

Rotameter, gas and fluid

SS H250/ RR/ M9/ ESK

nitrogen and water in:

indication local and DCS

coriolis flow meter

indication and control only local

Diphyl heating System

Bopp & Reuther

Bopp & Reuther

indication local and DCS

Pitot Tube Flow Measurement

indication local and DCS

indication local and

Instruments for level measurement

Diphyl heating System

switch contact to DCS

magnetic fold down level

Diphyl heating System

indication only local, switch contact to DCS

vibration level switch

Displacer (buoyancy) level transmitter

Guided level radar measurement

Guided level radar measurement

switch contact to DCS

http:/ /www.ksrkuebler.com/ website/ index.php?lang=en&load

indication local and DCS

indication local and DCS

5.1 Conceptual Formulation for electrical, instrumentation and DCS-system

Instruments for pressure measurement

SS RCh 100-3 with limit switch

membrane pressure gauge

SS RCh 100-3 with MDM 7210

membrane pressure transmitter

differential pressure transmitter

melt pressure transmitter

melt pressure transmitter with temperature sensor

http:/ /armaturenbau.com/ Datenblaetterpdf/ 1201-eng.pdf

indication only local, switch contact to DCS

http:/ /armaturenbau.com/ Datenblaetterpdf/ 1291-eng.pdf

gauge with Diaphragm Seal, indication only

http:/ /armaturenbau.com/ Datenblaetterpdf/ 7210-eng.pdf

Instruments for temperature measurement