Assignment Project report:
Involve an interconnected project relating to the Simtronics SPM720 and corresponding P&IDs available on the remote labs.
The cluster of assessments will involve a client case of an existing refinery; depicted in the Simtronic DCS/P&IDs; whose control system is reaching its end-of-life and requires adapting to the Rockwell architecture.
Part 1: Conceptual Model
The report must be structured as follows:
a) Title Page
b) Abstract
c) Table of Contents
d) Introduction
e) Literature Review
f) Case Studies
g) References
h) Appendices
Read carefully through the following guidelines relating to certain sections before commencing the activity.
Abstract:
Provide some high-level discussion describing what the DCS system actually does and its benefits to industry. Discuss emerging trends and the drivers for upgrades amongst which there might be the need for alignment with revised governances typically over environmental considerations. Include some discussion on the latest features available in Industry 4.0 revolution.
Literature review:
The literature review is required to develop a conceptual model to establish a clear and concise definition of user requirements for automation upgrades. The research must identify all significant drivers to automation upgrades to refineries, looking at literature and case studies available in trade books, articles in journals and the slides and reading material for this course in Moodle.
Significant drivers might include evolving governance, end of life equipment, safety, reliability, expandability and emerging trends. Also to be considered are the benefits available in the latest generation of Industry 4.0 product offerings of automation vendors.
The literature review needs to briefly discuss management of the automation project and of the communications and interactions between the various functions and groups. There will be design, construction and commissioning activities beyond the automation vendor scope and all the interfaces and communications must be managed carefully. The main groups are listed below.
a) Client (Operator)
b) Project Management Team
c) Design Engineers
d) Automation System Package Vendor
e) Construction
f) Field Engineering
When writing the thesis, consider the documentation requirements within each of the functions above, and the intercommunication required to share required information. For a simple example, in order for the automation vendor to be able to design the field cable interfaces inside termination cabinets, the design engineers must provide the automation system vendor with details of the field signal on each multicore cable pair.
Conversely, the automation vendor must provide the point/tag allocations for the analogue or discrete signal interface at the I/O module, this to enable designers to produce loop diagrams that the construction team will use to perform pre-commissioning loop tests.
Part 2: Requirements Definition
Requirements definition:
The conceptual model developed in Part One identifies key points to be considered within the functional design of an automation system upgrade. The model will now be applied to the case project.
A sample of P&IDs relating to the existing process is made available to the project. These are listed below.
a) Feed System
b) Distillation Column
c) Overhead System
d) Tank Farm
e) Flare System
For the purposes of sizing the I/O of the system and performing the preliminary design, it can be assumed that the DCS functionality represented on these P&ID sheets represents 5% of the overall scope.
Functional Design Specification:
A functional design specification can be brief or detailed, single or multi-document, depending on size, complexity and breakdown of the process to be measured and controlled. It should provide the following information.
- Details of how each area of the plant operates under automatic control (control philosophy)
- Details of the operator interfaces, i.e. screen layouts, navigation charts, alarm handling, trending and reporting
- Details of the Network architecture
- Details of any local operator interfaces.
For the purposes of the study and this assignment, produce a brief FDS that is not too detailed but that reflects on an upgrade to the refinery depicted on the five P&IDs listed. Include within the FDS a statement to the effect that these represent an estimate 5% of the overall functionality in the upgrade scope.
Integrate the user requirements, hardware, system requirements and consider the data communications. Consider the interfaces and interaction with field devices such as sensors, actuators, panels and rotating equipment, etc., operator interfaces, consoles, graphics, alarm handing, etc., power supplies, data communications, termination cabinets, barriers and terminals, etc. operator interface displays and their locations, equipment racks with power supply, comms, CPU and I/O modules in logical locations in weatherproof enclosures, local operator houses or in the central control buildings. There are no existing layout drawings available of this fictitious facility so just assume the locations and distances involved listing these as further assumptions within the FDS.
Note here that it is not unusual for an automation project to commence in this manner with sparse information as the historic management of records on some legacy assets can be poor. Any assumptions can be listed for management on a project risk register until these are replaced with actual findings.
A high-level architecture diagram reflecting your design may be included to clarify your requirements.
Bid Evaluation and Vendor Selection:
An automation upgrade is more often than not an outsourced service provided by an automation system vendor. For this purpose, the FDS forms the basis of design to be attached to an invitation to tender (ITT) published by the client procurement team. It is important for the engineering function representing the purchaser to extract some key technical attributes from the FDS for bid evaluation. The procurement team will also identify commercial attributes to be included in the evaluation. The cumulative technical and commercial scoring against these attributes will determine the best tender.
On conclusion of the FDS, provide a table listing the ten technical attributes chosen for this purpose.
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